Dodge - Dakota 4wd - Workshop Manual - 2009 - 2009

Factory Workshop Manual Make Dodge Model Durango 4wd Engine and year V8-5.7L Hybrid (2009) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Accessory Delay Relay is located in the Junction Block (JB). Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8 Accessory Delay Relay: Diagrams Connector (IN JB) RELAY-ACCESSORY DELAY (IN JB) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Sentry Key Immobilizer Module (SKREEM) - Description Alarm Module: Description and Operation Sentry Key Immobilizer Module (SKREEM) - Description DESCRIPTION The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM), and is also known as the Sentry Key Immobilizer Module (SKIM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Several unique SKREEM modules are used: one for vehicles equipped with RKE only, one for vehicles equipped with RKE and SKIS, and another version has an additional coaxial connector receptacle that allows it to receive inputs from the optional remote start antenna module. The SKREEM cannot be adjusted or repaired. If ineffective or damaged, the entire SKREEM unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Sentry Key Immobilizer Module (SKREEM) - Description > Page 13 Alarm Module: Description and Operation Sentry Key Immobilizer Module (SKREEM) - Operation OPERATION The Sentry Key REmote Entry Module (SKREEM) (also known as the Sentry Key Immobilizer Module/SKIM or the Wireless Control Module/WCM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver and may receive RF inputs either directly through an internal antenna from the RKE key fob transmitter or, on vehicles equipped with an optional remote start system, indirectly through the external remote start antenna module. See: Body and Frame/Locks/Power Locks/Description and Operation/Power Locks Description. The SKREEM communicates over the Controller Area Network (CAN) data bus with the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Powertrain Control Module (PCM), or the diagnostic scan tool. The SKREEM and the PCM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code, called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM during SKIS initialization. In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM using the diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends an electronic valid key message to the PCM over the CAN data bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKREEM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends electronic security indicator request messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator request message from the SKREEM tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator request messages to the EMIC to turn the indicator OFF, turn the indicator ON, or to flash the indicator ON and OFF. If the security indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction or if the SKIS has become ineffective, the security indicator will stay ON solid. If the SKREEM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Service and Repair. The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The hard wired circuits of the SKREEM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKREEM or the electronic controls or communication between other modules and devices that provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose the SKREEM or the electronic controls and communication related to SKREEM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) Removal Alarm Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push gently inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) Removal > Page 16 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. On vehicles equipped with the optional remote start system, disconnect the coaxial cable from the coaxial connector receptacle on the SKREEM. 10. Remove the screw (2) that secures the SKREEM (1) to the steering column housing. 11. Disengage the antenna ring (3) from around the ignition lock cylinder housing (4) and remove the SKREEM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) Removal > Page 17 Alarm Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column with the antenna ring (3) oriented around the ignition lock cylinder housing (4). 2. Install and tighten the screw (2) that secures the SKREEM to the steering column housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). 4. On vehicles equipped with the optional remote start system, reconnect the coaxial cable to the coaxial connector receptacle on the SKREEM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) Removal > Page 18 5. Position the lower shroud (3) onto the steering column (4). 6. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 7. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 8. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 9. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 10. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 11. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), if the Sentry Key REmote Entry Module (SKREEM) is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C1 (Headliner) 16 Way Entertainment System Control Module: Diagrams Satellite Video Module C1 (Headliner) 16 Way Connector C1 - (HEADLINER) 16 WAY MODULE-SATELLITE VIDEO - (HEADLINER) 16 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C1 (Headliner) 16 Way > Page 23 Entertainment System Control Module: Diagrams Satellite Video Module C2 (Body Left) 2 Way Connector C2 - (BODY LEFT) 2 WAY MODULE-SATELLITE VIDEO - (BODY LEFT) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C1 (Headliner) 16 Way > Page 24 Entertainment System Control Module: Diagrams Satellite Video Module C3 (Body Left) 2 Way Connector C3 - (BODY LEFT) 2 WAY MODULE-SATELLITE VIDEO - (BODY LEFT) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C1 (Headliner) 16 Way > Page 25 Entertainment System Control Module: Diagrams Satellite Video Module C4 (Body) 2 Way Connector C4 - (BODY) 2 WAY MODULE-SATELLITE VIDEO - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Description and Operation > Satellite Video Module Description Entertainment System Control Module: Description and Operation Satellite Video Module Description DESCRIPTION The satellite receiver module is located above the headliner near the rear liftgate opening. It is mounted to the roof panel with three mounting fasteners. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Description and Operation > Satellite Video Module Description > Page 28 Entertainment System Control Module: Description and Operation Satellite Video Module Operation OPERATION The satellite receiver module receives signals from the roof mounted antenna and processes this information before it is sent to the radio. The module operates on both battery feed circuits and CAN bus messages. It will operate with the ignition key in the run or accessory position only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Service and Repair > Satellite Video Module - Removal Entertainment System Control Module: Service and Repair Satellite Video Module - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Lower the headliner as necessary. 3. Remove the mounting bracket fasteners. 4. Disconnect the antenna and electrical harness connectors. 5. Remove the module from the mounting bracket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Service and Repair > Satellite Video Module - Removal > Page 31 Entertainment System Control Module: Service and Repair Satellite Video Module - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Connect antenna and electrical harness connector to module. 2. Install module to mounting bracket. Tighten mounting fasteners. 3. Position module and bracket. Install new mounting fasteners. 4. Install headliner. 5. Connect battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 35 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY MODULE-WIRELESS CONTROL - (INSTRUMENT PANEL) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 36 Keyless Entry Module: Testing and Inspection SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 37 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Park Assist Module C1 (Parktronics) 12 Way Parking Assist Control Module: Diagrams Park Assist Module C1 (Parktronics) 12 Way Connector C1 (PARKTRONICS) - 12 WAY MODULE-PARK ASSIST (PARKTRONICS) - 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Park Assist Module C1 (Parktronics) 12 Way > Page 43 Parking Assist Control Module: Diagrams Park Assist Module C2 (Parktronics) 8 Way Connector C2 (PARKTRONICS) - 8 WAY MODULE-PARK ASSIST (PARKTRONICS) - 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Description and Operation > Park Assist Module - Description Parking Assist Control Module: Description and Operation Park Assist Module - Description DESCRIPTION The Park Assist Module (3) is secured with three push-in plastic fasteners through three mounting tabs (2) integral to the module housing to the left inner quarter panel above the left rear wheel housing. The module is concealed beneath the quarter inner trim panel. Concealed within the molded plastic park assist module housing is a microprocessor and the other electronic circuitry of the module. The module housing is sealed to enclose and protect the internal electronic circuitry. The module software is flash programmable. Two connector receptacles (1) containing terminal pins are integral to the rearward-facing side of the housing. The module is connected to the vehicle electrical system through two dedicated take outs and connectors of the body wire harness. The park assist module cannot be adjusted or repaired and, if damaged or ineffective, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Description and Operation > Park Assist Module - Description > Page 46 Parking Assist Control Module: Description and Operation Park Assist Module - Operation OPERATION The microprocessor in the park assist module contains the park assist system logic circuits. The module uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is also used for park assist system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The module provides voltage to the four park assist sensors located behind the rear bumper fascia and to the park assist display located in the headliner just forward of the liftgate opening header. The module then monitors return inputs from each of the sensors and the display on dedicated hard wired data communication circuits. The sensor inputs allow the module to determine when an obstacle is in the rear path of the vehicle and enables the module to calculate the relative location of the obstacle, and whether the distance to that obstacle is increasing or decreasing. Pre-programmed decision algorithms and calibrations allow the module microprocessor to determine the appropriate park assist system outputs based upon the inputs received from the park assist sensors and electronic messages received from other modules in the vehicle over the CAN data bus. When the programmed conditions are met the module sends electronic messages to the park assist displays over a dedicated serial bus to obtain the proper park assist system visual and audible outputs. The module also broadcasts electronic messages over the CAN data bus to enable the other electronic features of the park assist system. The park assist module microprocessor continuously monitors all of the park assist system electrical circuits and components to determine the system readiness. If the module detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and sends the appropriate electronic messages to the instrument cluster over the CAN data bus to control operation of certain park assist system audible warnings and textual messages displayed in the Electronic Vehicle Information Center (EVIC). The park assist module receives battery current on a fused ignition switch output (run-start) circuit through a fuse in the Junction Block (JB). The module receives ground through a ground circuit and take out of the body wire harness. These connections allow the module to be operational whenever the ignition switch is in the START or ON positions. The hard wired circuits between components related to the park assist module may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the park assist module or the electronic controls or communication between modules and other devices that provide some features of the park assist system. The most reliable, efficient, and accurate means to diagnose the park assist module or the electronic controls and communication related to park assist module operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Service and Repair > Park Assist Module - Removal Parking Assist Control Module: Service and Repair Park Assist Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the trim from the left quarter inner panel to access the park assist module (5), which is located behind the power liftgate module (3) to the rear of the C-pillar (2) and above the left rear wheel housing. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel Removal. 3. Disconnect the two body wire harness connectors (1) from the park assist module connector receptacles. 4. Remove the three plastic push-in fasteners (4) that secure the module to the left quarter inner panel. 5. Remove the module from the left quarter inner panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Service and Repair > Park Assist Module - Removal > Page 49 Parking Assist Control Module: Service and Repair Park Assist Module - Installation INSTALLATION 1. Position the park assist module (5) to the left quarter inner panel, behind the power liftgate module (3) to the rear of the C-pillar (2) and above the left rear wheel housing. 2. Secure the module to the left quarter inner panel using three plastic push-in fasteners (4). 3. Reconnect the two body wire harness connectors (1) to the module connector receptacles. 4. Reinstall the trim onto the left quarter inner panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 5. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 53 Voice Activation Module: Diagrams Connector - (INSTRUMENT PANEL) 22 WAY MODULE-HANDS FREE - (INSTRUMENT PANEL) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Driver Door Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Locations > Driver Door Module > Page 59 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C1 (Front Driver Door) 10 Way Door Module: Diagrams Driver Door Module C1 (Front Driver Door) 10 Way Connector C1 - (FRONT DRIVER DOOR) 10 WAY MODULE-DOOR-DRIVER - (FRONT DRIVER DOOR) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C1 (Front Driver Door) 10 Way > Page 62 Door Module: Diagrams Driver Door Module C2 (Front Driver Door) 20 Way Connector C2 - (FRONT DRIVER DOOR) 20 WAY MODULE-DOOR-DRIVER - (FRONT DRIVER DOOR) 20 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C1 (Front Driver Door) 10 Way > Page 63 Door Module: Diagrams Driver Door Module C3 (Front Driver Door) 12 Way Connector C3 - (FRONT DRIVER DOOR) 12 WAY MODULE-DOOR-DRIVER - (FRONT DRIVER DOOR) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C1 (Front Driver Door) 10 Way > Page 64 Door Module: Diagrams Passenger Door Module C1 (Front Passenger Door) 10 Way Connector C1 - (FRONT PASSENGER DOOR) 10 WAY MODULE-DOOR-PASSENGER - (FRONT PASSENGER DOOR) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Diagrams > Driver Door Module C1 (Front Driver Door) 10 Way > Page 65 Door Module: Diagrams Passenger Door Module C2 (Front Passenger Door) 20 Way Connector C2 - (FRONT PASSENGER DOOR) 20 WAY MODULE-DOOR-PASSENGER - (FRONT PASSENGER DOOR) 20 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Description and Operation > Door Module - Description Door Module: Description and Operation Door Module - Description DESCRIPTION There are two Door Modules, Driver Door Module (DDM) and Passenger Door Modules (PDM). One located in the driver door and one in the passenger door, just behind the door trim panel. The modules send a bus message to the power mirrors to adjust them to a preset position when a memory recall request has been made. The memory mirror modules also act as an interface in each door for electrical functions (door lock switches and door ajar switches). The Memory System makes available for immediate recall personalized preferences of the following: - Automatic temperature control settings. - Outside mirror positions. - Power adjustable brake and accelerator pedal position. - Power seat horizontal, vertical, recliner, and easy entry positions. - Radio push button station selections. The major components of the Memory System are: - Memory Selector Switch - located in the driver door trim panel. - Driver Door Module (DDM) - located in the driver door, behind the trim panel. - Passenger Door Module (PDM) - located in the passenger door, behind the trim panel. - Sentry Key Remote Entry Module (SKREEM) - located at ignition key cylinder. - Remote Keyless Entry (RKE) Transmitter - located with ignition key. - Memory Seat Module (MSM) - located underneath the driver seat and also controls the Adjustable Pedals. - Radio - located in the instrument panel center stack. - Automatic Temperature Control (ATC) - located in the instrument panel center stack. The memory recall is available at the press of a button on the drivers door trim panel or, by using the Remote Keyless Entry (RKE) transmitter if it is programmed to trigger the recall. Radio settings include up to 20 push button presets (10 AM and 10 FM), and the last station selection, even if it is not one of the 20 preset selections. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Description and Operation > Door Module - Description > Page 68 Door Module: Description and Operation Door Module - Operation OPERATION The door modules receives input from the door lock switches and sends that message to the cluster for door lock operation (vehicles equipped with memory system only). It also controls the mirror adjustment by receiving input from the mirror switch on the door trim panel. Sensors in the mirrors act as inputs to the memory mirror module in order to position the mirrors to presets by the driver(s). The power supply to the mirrors is supplied by the door modules. On vehicles equipped with a memory system, the front door ajar switches are inputs to the door module. The modules use this information for door lock inhibit etc. A memory setting is saved by pressing the "set" button, then pressing either the memory "1" or "2" button within 5 seconds of pressing the "set" button. A memory setting is recalled by pressing either the memory "1" or "2" button, or by pressing the unlock button on a "linked" Remote Keyless Entry (RKE) transmitter. For driver safety, memorized settings can not be recalled if the transmission is in a position other than Park or the seat belt is latched. Both driver and passenger modules provide active and stored Diagnostic Trouble Codes (DTC's) to aid in diagnosis. Both modules are identical in appearance with the exception of an extra ground wire on the driver side memory mirror module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Door Module: Component Tests and General Diagnostics DOOR MODULE Any diagnosis of the memory mirror module should begin with the use of a scan tool and the appropriate Diagnostic information. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Service and Repair > Door Module - Removal Door Module: Service and Repair Door Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal. 3. First disconnect the black 10-way electrical connector (1), then the brown 20-way electrical connector (2). If applicable, next disconnect the black 12-way electrical connector (3) from the module. 4. Remove fasteners and module from vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Door Module > Component Information > Service and Repair > Door Module - Removal > Page 73 Door Module: Service and Repair Door Module - Installation INSTALLATION 1. Position module on door and install fasteners. 2. If applicable, first connect the black 12-way electrical connector (3), then connect the brown 20-way electrical connector (2). Then connect the black 10-way electrical connector to the module (1). 3. Install the door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. 4. Connect the battery negative cable. 5. Verify system and vehicle operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 77 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY MODULE-WIRELESS CONTROL - (INSTRUMENT PANEL) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 78 Keyless Entry Module: Testing and Inspection SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 79 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way Memory Positioning Module: Diagrams Memory Seat Module C1 (Left Seat) 14 Way Connector C1 - (LEFT SEAT) 14 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 85 Memory Positioning Module: Diagrams Memory Seat Module C2 (Left Seat) 6 Way Connector C2 - (LEFT SEAT) 6 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 86 Memory Positioning Module: Diagrams Memory Seat Module C3 (Left Seat) 14 Way Connector C3 - (LEFT SEAT) 14 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 87 Memory Positioning Module: Diagrams Memory Seat Module C4 (Left Seat) 6 Way Connector C4 - (LEFT SEAT) 6 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 88 Memory Positioning Module: Diagrams Memory Seat Module C5 (Adjustable Pedals) 6 Way Connector C5 (ADJUSTABLE PEDALS) - 6 WAY MODULE-SEAT MEMORY (ADJUSTABLE PEDALS) - 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Description and Operation > Memory Seat Module - Description Memory Positioning Module: Description and Operation Memory Seat Module - Description DESCRIPTION NOTE: The scan tool standardization process must be performed on the Memory Seat Module (MSM) any time a new module is installed or the existing module is reflashed. The Memory Seat Module (MSM) is located underneath the driver seat, towards the front and on the outboard side. It is used in conjunction with the other modules in the memory system See: Memory Seat Module - Operation to recall the seat to one of two preset seat functional adjustments (horizontal, vertical, and recliner). The switch for the memory seat programming and selection mounts on the driver door trim panel. The MSM also controls the adjustable pedals, both for the memory and manual functionality. The adjustable accelerator and brake pedals are available on SLT and Limited models. On Limited, their positioning can be stored for recall by the memory system, allowing for two drivers to have unique, pre-programmed settings. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Description and Operation > Memory Seat Module - Description > Page 91 Memory Positioning Module: Description and Operation Memory Seat Module - Operation OPERATION POWER/MEMORY SEAT The memory seat module receives input from the 8-way power seat switch, the driver seat position sensors, adjustable pedal control circuits (switch, sensor, and motor), and the data bus circuit. The memory switch, is wired to the memory mirror module which sends the message over the data bus. The memory seat module performs the following functions: - Positions the driver seat (vertical, horizontal, and recliner positions) and adjustable pedals. - Sends the memory save or recall (#1 or #2) command over the data bus circuit to the memory mirror modules, HVAC, and radio. - Provides for "linking" the key FOBs to memory. - Provides for the easy entry/exit feature. - Provides the tilt mirrors in reverse feature When a memory button is pressed (#1 or #2) on the memory switch, the driver door memory mirror module sends a recall message to the memory seat module (MSM). Then the MSM will position the driver seat and adjustable pedals to its preprogrammed location/setting. When the Remote Keyless Entry (RKE) Transmitter button is pressed, depending on which transmitter (#1 or #2), the SKREEM (RKE Receiver) sends the recall request and FOB number (#1 or #2) data message. This RKE transmitter function depends on if the MSM is programmed to trigger the recall (linked FOBs). A memory setting is saved by pressing the "set" button, then pressing either the memory "1" or "2" button within 5 seconds of pressing the "set" button. A memory setting is recalled by pressing either the memory "1" or "2" button, or by pressing the unlock button on a "linked" Remote Keyless Entry (RKE) transmitter. For driver safety, memorized settings can not be recalled if the transmission is in any position other than park or the seat belt is latched. A key FOB is "linked" to a memory setting by pressing the "set" button and then pressing either the memory "1" or "2" button within 5 seconds of pressing the set button, then by pressing the "lock" button on the selected key FOB. The memory system "Easy Entry and /Exit" feature provides the driver with more room to enter or exit the vehicle. The Easy Entry and Exit feature is disabled when the vehicle leaves the factory. An authorized dealer can enable this feature. When the seat is in a memorized position, it will move rearward 55 millimeters or to the end of its travel, whichever occurs first, when the key is removed from the ignition switch lock cylinder. The seat will return to the memory position when the driver turns the vehicle's ignition switch out of the LOCK position. The memory system "learns" the seat and adjustable pedal motor maximum end positions when the motor reaches the limit of travel in any direction and stalls. Subsequently, movement will stop just short of that position to avoid extra stress on the motors and mechanisms. If the system learned a maximum position as a result of an obstruction, as for instance if a large object was placed on the floor behind the seat, the system can relearn the "true" maximum position through manually operating the power seat after the obstruction is removed. NOTE: It is normal for the power accessories contained in the memory system to stop at the maximum "learned" position and then continue to the "true" maximum position when the control switch is released and then applied in the same direction a second time. Certain functions and features of the memory system rely upon resources shared with other electronic modules in the vehicle over the Controller Area Network (CAN) bus. The CAN bus allows the sharing of sensor information. This helps to reduce wire harness complexity, internal controller hardware, and component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. For diagnosis of these electronic modules or of the CAN bus, the use of a scan tool and the proper diagnostic information are needed. The tilt mirrors in reverse feature provides for tilting the sideview (outside) mirrors down a predetermined angle, providing a better view of the ground next to the rear portion of the vehicle. The tilt mirrors in reverse feature is disabled when the vehicle leaves the factory. An authorized dealer can enable this feature. Operation of the tilt mirrors is as follows: - Sideview mirrors will tilt down when the vehicle transmission is shifted into Reverse. - Sideview mirrors will return to the original position when the vehicle transmission is shifted out of Reverse. ADJUSTABLE PEDALS The pedals swing on a large arc, the radius and angle of which were selected on the basis of ergonomic studies, that puts them in the proper position for use by the smaller driver - higher and angled upward as well as rearward. Powered by the small electric motor driving a gear train at each pedal, adjustment is precise, quiet, and smooth throughout the range. A paddle-type switch on the instrument panel to the left of the steering column actuates the electric motor-driven mechanism through the memory seat module (MSM). Pushing up the paddle brings the pedals closer and vice versa. Movement Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Description and Operation > Memory Seat Module - Description > Page 92 stops when the switch is released. MSM logic prevents pedal adjustment when the automatic speed control (cruise control) is set (controlling speed), and when the transmission is in reverse. This feature protects against a loss of reference position when neither foot is on the pedal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Description and Operation > Page 93 Memory Positioning Module: Testing and Inspection MEMORY SEAT MODULE Any diagnosis of the memory seat system/module should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Module - Removal Memory Positioning Module: Service and Repair Memory Seat Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver seat cushion/cover (2) See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 3. Unsnap the memory seat module (4) from the side brackets. 4. Pivot the module upward and disconnect the electrical connectors (1). 5. Pull the module rearward to remove it from the front of the seat frame (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Module - Removal > Page 96 Memory Positioning Module: Service and Repair Memory Seat Module - Installation INSTALLATION 1. Place the module (4) into position making sure the front snaps into the seat frame (3). 2. Connect the memory seat module harness connectors (1). 3. Pivot the module (4) downward and snap it into place in the side brackets. 4. Install the driver seat cushion/cover (2) See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Installation. 5. Connect the battery negative cable. 6. Using an appropriate scan tool go to the MSM miscellaneous functions and perform the standardization routine. 7. Verify system and vehicle operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Relay > Component Information > Locations Pedal Positioning Relay: Locations Adjustable Pedals Relay is located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Pedal Positioning Relay > Component Information > Locations > Page 100 Pedal Positioning Relay: Diagrams Connector (IN IPM) RELAY-ADJUSTABLE PEDALS (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Power Liftgate Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Power Liftgate Module > Page 105 Power Trunk / Liftgate Control Module: Locations Power Liftgate Module C2 (Body) 22 Way Connector C2 - (BODY) 22 WAY MODULE-POWER LIFTGATE - (BODY) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Power Liftgate Module > Page 106 Power Trunk / Liftgate Control Module: Locations Power Liftgate Module C3 (Body) 2 Way Connector C3 - (BODY) 2 WAY MODULE-POWER LIFTGATE - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Diagrams > Power Liftgate Module C1 (Body) 12 Way Power Trunk / Liftgate Control Module: Diagrams Power Liftgate Module C1 (Body) 12 Way Connector C1 - (BODY) 12 WAY MODULE-POWER LIFTGATE - (BODY) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Diagrams > Power Liftgate Module C1 (Body) 12 Way > Page 109 Power Trunk / Liftgate Control Module: Diagrams Power Liftgate Module C2 (Body) 22 Way Connector C2 - (BODY) 22 WAY MODULE-POWER LIFTGATE - (BODY) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Diagrams > Power Liftgate Module C1 (Body) 12 Way > Page 110 Power Trunk / Liftgate Control Module: Diagrams Power Liftgate Module C3 (Body) 2 Way Connector C3 - (BODY) 2 WAY MODULE-POWER LIFTGATE - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Description and Operation > Power Liftgate Control Module - Description Power Trunk / Liftgate Control Module: Description and Operation Power Liftgate Control Module Description DESCRIPTION Vehicles equipped with a power liftgate system utilize a power liftgate control module (4). This module is located on the left side of the vehicle behind the C-pillar below the quarter glass The power liftgate control module receives and monitors logic inputs from all the power liftgate system switches. This module also contains the software technology to detect liftgate obstructions and stop or reverse the door accordingly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Description and Operation > Power Liftgate Control Module - Description > Page 113 Power Trunk / Liftgate Control Module: Description and Operation Power Liftgate Control Module Operation OPERATION The power liftgate control module contains the electronic circuitry and software used to control the sequence of events for the power liftgate system. This module communicates on the Controller Area Network (CAN) to monitor many different inputs and outputs such as door lock status, transmission gear selector position and vehicle speed. The power liftgate open/close command can be initiated by either one press of the power liftgate overhead console switch or two presses of the key fob power liftgate switch. The overhead switch is hardwired to the power liftgate control module. The key fob, sends a signal out on the Controller Area Network (CAN) Data Bus circuit. This signal is detected at the Power Liftgate Control Module. The power liftgate control module then interprets the information to confirm safety requirements are met before applying power to the power liftgate drive unit to start a power cycle. During a power liftgate open or close cycle, if the power liftgate control module detects sufficient resistance to liftgate travel, such as an obstruction in the liftgate's path. The control module will immediately stop liftgate movement and reverse the direction of travel to the full open or closed position. The power liftgate control module has the ability to relearn. After 8 miles have been recorded on the odometer, anytime the liftgate is fully opened and fully closed using the automatic system, the module will learn from its cycle. If a replacement power liftgate component is installed or a liftgate adjustment is made, the module will relearn the effort and time required to open or close the liftgate. This learn cycle can be performed with a Diagnostic Scan Tool or with a complete cycle of the liftgate, using either one of the command switches. See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Testing and Inspection/Programming and Relearning for detailed instructions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Description and Operation > Page 114 Power Trunk / Liftgate Control Module: Testing and Inspection POWER LIFTGATE CONTROL MODULE Any diagnosis of the Power Liftgate System should begin with the use of a diagnostic scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Procedures Information. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. Before any testing of the power liftgate system is attempted, the battery should be fully-charged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Service and Repair > Power Liftgate Control Module - Removal Power Trunk / Liftgate Control Module: Service and Repair Power Liftgate Control Module Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left quarter trim panel from the vehicle, See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the wire harness connectors (2) from the power liftgate control module (4). 4. Using molding remover C-4829A gently pry the clip (1) out of the retaining hole holding the power liftgate control module (4) to the quarter panel. 5. Tilt the top of the module (4) away from the quarter panel and lift upward to disengage the mounting tab from the locating slot (3). 6. Remove the power liftgate control module (4) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Service and Repair > Power Liftgate Control Module - Removal > Page 117 Power Trunk / Liftgate Control Module: Service and Repair Power Liftgate Control Module Installation INSTALLATION 1. Position the power liftgate control module (4) into the vehicle. 2. Insert the mounting tab into the locating slot (3) on the quarter panel. 3. Tilt the top of the module (4) toward the quarter panel and firmly press the clip (1) into the retaining hole on the quarter panel. 4. Connect the wire harness connectors (2) to the power liftgate control module (4). 5. Install the left quarter trim panel, See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 6. Connect the battery negative cable. 7. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes. 8. Perform the power liftgate learn cycle, See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Testing and Inspection/Programming and Relearning. 9. Verify power liftgate system operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 121 Seat Heater Control Module: Diagrams Connector - (BODY) 6 WAY MODULE-HEATED SEAT - (BODY) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description Seat Heater Control Module: Description and Operation Heated Seat Module - Description DESCRIPTION The heated seat module (2) is located behind the right rear D-pillar trim (1). The heated seat module has a single electrical connector (3). The heated seat module is an microprocessor designed to use CAN bus messages from the cluster Cabin Compartment Node (CCN) to operate the heated seat elements in both front seats. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description > Page 124 Seat Heater Control Module: Description and Operation Heated Seat Module - Operation OPERATION The heated seat module operates on fused battery current received from the ignition switch. The module is grounded at all times through a ground lug on the right rear D-pillar. Inputs to the module include CAN bus messages and standard hardwired 12volt power and ground. In response to those inputs the heated seat module controls the battery current to the heated seat elements. When a heated seat switch CAN bus signal is received by the heated seat module, the module energizes the selected heated seat element. The Low heat set point is about 38°C (100.4°F), and the High heat set point is about 42°C (107.6°F). If the heated seat module detects a heated seat element OPEN or SHORT circuit, it will record and store an diagnostic trouble code (DTC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 125 Seat Heater Control Module: Testing and Inspection HEATED SEAT MODULE 1. Test the appropriate heated seat element See: Body and Frame/Seats/Seat Heater/Testing and Inspection. 2. Test the appropriate heated seat switch. 3. Using a voltmeter, backprobe the heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12v should be present. If OK go to 4 , if Not, repair the open or shorted voltage supply circuit as required. 4. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK test the Cabin compartment Node (CCN) cluster using a scan tool for proper heated seat system function. If Not OK, Repair the open or shorted ground circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal Seat Heater Control Module: Service and Repair Heated Seat Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the liftgate and remove the upper D-pillar trim from the vehicle. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Removal. 3. Remove the lower D-pillar trim from the vehicle. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Removal. 4. Disconnect the wire harness connector from the back of the heated seat module (2). 5. Unsnap the heated seat module (2) from the D-pillar (1). 6. Remove the heated seat module (2) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal > Page 128 Seat Heater Control Module: Service and Repair Heated Seat Module - Installation INSTALLATION 1. Install the heated seat module on the D-pillar (1). 2. Connect the wire harness connector (3) to the heated seat module (2). 3. Reconnect the negative battery cable. 4. Check for proper heated seat system operation. 5. Install the upper and lower D-pillar trim to the vehicle. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Installation. 6. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Trailer Towing Relay: Locations Trailer Tow Left and Right Relays are located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Relay-Trailer Tow-Left Trailer Towing Relay: Diagrams Relay-Trailer Tow-Left Connector (IN IPM) RELAY-TRAILER TOW-LEFT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Relay-Trailer Tow-Left > Page 134 Trailer Towing Relay: Diagrams Relay-Trailer Tow-Right Connector (IN IPM) RELAY-TRAILER TOW-RIGHT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description Trailer Towing Relay: Description and Operation Trailer Tow Relay - Description DESCRIPTION Vehicles equipped with an optional factory-installed trailer towing package have two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description > Page 137 Trailer Towing Relay: Description and Operation Trailer Tow Relay - Operation OPERATION The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays as well as the hard wired inputs and outputs of the relays may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Antilock Brake Module (Headlamp And Dash Side) 38 Way Electronic Brake Control Module: Diagrams Antilock Brake Module (Headlamp And Dash Side) 38 Way Connector - (HEADLAMP AND DASH SIDE) 38 WAY MODULE-ANTILOCK BRAKES - (HEADLAMP AND DASH SIDE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Antilock Brake Module (Headlamp And Dash Side) 38 Way > Page 144 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Antilock Brake Module (Headlamp And Dash Side) 38 Way > Page 145 Electronic Brake Control Module: Diagrams Antilock Brake Module (HEV) (Headlamp And Dash) 47 Way Connector (HEV) - (HEADLAMP AND DASH) 47 WAY MODULE-ANTILOCK BRAKES (HEV) - (HEADLAMP AND DASH) 47 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Antilock Brake Module (Headlamp And Dash Side) 38 Way > Page 146 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module - Description Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Description DESCRIPTION The Antilock Brake Module (ABM) is a microprocessor which handles testing, monitoring and controlling the ABS brake system operation. The ABM is mounted on the top of the hydraulic control unit (HCU). The ABM operates the ABS system and is separate from other vehicle electrical circuits. ABM voltage source is through CKT A111 (fused B+). NOTE: If the ABM needs to be replaced, Perform the ABS verification using a scan tool. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module - Description > Page 149 Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Operation ABS Unit ABS UNIT SYSTEM SELF-TEST When the ignition switch is turned-on the microprocessor is tested. If an error occurs during the test, a DTC will be set into the memory. However it is possible the DTC will not be stored in memory if the error has occurred in the module were the DTC's are stored. The ABM contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in memory and are accessible with the scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. ABM INPUTS The ABM continuously monitors the speed of the vehicle by monitoring signals generated by the wheel speed sensors. The ABM determines a wheel locking tendency when it recognizes the axle is decelerating too rapidly. The ABM monitors the following inputs to determine when a wheel locking tendency may exists: - Wheel Speed Sensors - Brake Lamp Switch - Brake Fluid Level Sensor (CAN C BUS) - G-Sensor (4X4) ABM OUTPUTS The ABM requests the following outputs for antilock braking and brake warning information from the CCN via CAN C Bus: - ABS Warning Lamp - Brake Warning Lamp ESP Unit ESP UNIT - (ELECTRONIC STABILITY PROGRAM) SYSTEM SELF-TEST When the ignition switch is turned-on the microprocessor is tested. If an error occurs during the test, a DTC will be set into the memory. However it is possible the DTC will not be stored in memory if the error has occurred in the module were the DTC's are stored. The ABM contains a self check program that illuminates the ABS and ESP warning lights when a ABS system fault is detected. If only the ESP light is illuminated ESP system fault is detected. Faults are stored in memory and are accessible with the scan tool. System faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. ABM INPUTS The ABM continuously monitors the speed of the vehicle by monitoring signals generated by the wheel speed sensors. The ABM determines a wheel locking tendency when it recognizes the axle is decelerating too rapidly. The ABM monitors the following inputs to determine when a wheel locking tendency may exists: - Wheel Speed Sensors - Brake Lamp Switch - Brake Fluid Level Sensor (CAN C BUS) - Steering Angle Sensor (SAS) (CAN C BUS) - Dynamic Sensor - ESP Off Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module - Description > Page 150 - Vacuum Sensor ABM OUTPUTS The ABM requests the following outputs for antilock braking and brake warning information from the CCN via CAN C Bus: - ABS Warning Lamp - Brake Warning Lamp - ESP Warning Lamp - ESP Function Lamp Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal Electronic Brake Control Module: Service and Repair Anti-Lock Brake System Module - Removal REMOVAL CAUTION: When removing ABM from HCU, be sure to completely separate the two components (approximately 38 mm (1.5 in.) before removing ABM. Otherwise, damage to the pressure sensor or Pump Motor connection may result requiring HCU replacement. Do not to touch the sensor terminals on the HCU side or the contact pads on the ABM side as this may result in contamination and issues in the future. NOTE: ABM module can be removed without removing the HCU unit. 1. Remove the left front tire and wheel assembly. 2. Disconnect the electrical connector from the ABM module. 3. Remove the module mounting screws (2). 4. Remove the module from the HCU (1) on ESP vehicles be careful not to damage the pressure sensor or not to touch the sensor terminals on the HCU side or the contact pads on the ABM side when removing the ABM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 153 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System Module - Installation INSTALLATION CAUTION: When removing ABM from HCU, be sure to completely separate the two components (approximately 38 mm (1.5 in.) before removing ABM. Otherwise, damage to the pressure sensor or Pump Motor connection may result requiring HCU replacement. Do not to touch the sensor terminals on the HCU side or the contact pads on the ABM side as this may result in contamination and issues in the future. 1. Position the module on the HCU on ESP vehicles be careful not to damage the pressure sensor or not to touch the sensor terminals on the HCU side or the contact pads on the ABM side when installing the ABM. 2. Install the mounting screws (2) and tighten to 2.5 Nm (22 in. lbs). 3. Connect the scan tool and initialize the ABM by performing the ABS Verification Test See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Vacuum Pump Relay, Brakes > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Vacuum Pump Relay, Brakes > Component Information > Locations > Page 157 Vacuum Pump Relay: Diagrams Connector (HEV) - (IN PDC) RELAY-VACUUM PUMP (HEV) - (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 162 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Condenser Cooling Fan Module (Gas) (Headlamp And Dash) 3 Way Radiator Cooling Fan Control Module: Diagrams Condenser Cooling Fan Module (Gas) (Headlamp And Dash) 3 Way Connector (GAS) - (HEADLAMP AND DASH) 3 WAY FAN MODULE-CONDENSER COOLING (GAS) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Condenser Cooling Fan Module (Gas) (Headlamp And Dash) 3 Way > Page 165 Radiator Cooling Fan Control Module: Diagrams HEV Radiator Cooling Fan Module (HEV) (Auxiliary Power Module) 4 Way Connector (HEV) - (AUXILIARY POWER MODULE) 4 WAY FAN MODULE-HEV RADIATOR COOLING (HEV) - (AUXILIARY POWER MODULE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Radiator Fan High and Low Relays are located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan High Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan High Connector (IN IPM) RELAY-RADIATOR FAN HIGH (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan High > Page 171 Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan Low Connector (IN IPM) RELAY-RADIATOR FAN LOW (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay Blower Motor Relay: Locations Front Blower Motor Relay Front Blower Motor Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 177 Blower Motor Relay: Locations Rear Blower Motor Relay Rear Blower Motor Relay is located in the Junction Block (JB). Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Relay-Blower Motor-Front Blower Motor Relay: Diagrams Relay-Blower Motor-Front Connector (IN PDC) RELAY-BLOWER MOTOR-FRONT (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Relay-Blower Motor-Front > Page 180 Blower Motor Relay: Diagrams Relay-Blower Motor-Rear Connector (IN JB) RELAY-BLOWER MOTOR-REAR (IN JB) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay - Description Blower Motor Relay: Description and Operation Front Blower Motor Relay - Description DESCRIPTION The blower motor relay (1) for the standard front heating-A/C system is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal function and patterns (2). The front blower motor relay is a electromechanical device that switches battery current from a fuse in the power distribution center (PDC) directly to the front blower motor when equipped with the manual temperature control (MTC) system, or the blower motor power module when equipped with the automatic temperature control (ATC) system. The front blower motor relay is energized when the relay coil is provided a ground circuit through the integrated power module. The front blower motor relay is located in the power distribution center (PDC) in the engine compartment. Refer to the PDC label for front blower motor relay identification and location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay - Description > Page 183 Blower Motor Relay: Description and Operation Front Blower Motor Relay - Operation OPERATION The ISO-standard front blower motor relay is an electromechanical switch that uses a low current input from the battery to control the high current output to the front blower motor. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the front blower motor. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The front blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the power distribution center (PDC). The inputs and outputs of the front blower motor relay include: - The common feed terminal (30) receives battery current through a fuse in the PDC at all times. - The coil ground terminal (85) receives a ground circuit through the integrated power module. - The coil battery terminal (86) receives battery current through a fuse in the PDC at all times. - The normally open terminal (87) provides battery current output to the front blower motor when equipped with the manual temperature control (MTC) system, or the blower motor power module when equipped with the automatic temperature control (ATC) system only when the front blower motor relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the front blower motor relay coil is de-energized. The front blower motor relay cannot be adjusted or repaired and must be replaced if inoperative or damaged. See Wiring Information for diagnosis and testing of the blower motor relay and for complete HVAC wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay - Description > Page 184 Blower Motor Relay: Description and Operation Rear Blower Motor Relay - Description DESCRIPTION The blower motor relay (1) for the rear heating-A/C system is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal function and patterns (2). The rear blower motor relay is a electromechanical device that switches battery current from a fuse in the junction block directly to the rear blower motor. The rear blower motor relay is energized when the relay coil is provided a voltage signal by the ignition switch. The rear blower motor relay is located in the junction block (JB) in the passenger compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay - Description > Page 185 Blower Motor Relay: Description and Operation Rear Blower Motor Relay - Operation OPERATION The ISO-standard rear blower motor relay is an electromechanical switch that uses a low current input from the ignition switch to control the high current output to the rear blower motor. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the rear blower motor. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the junction block (JB). The inputs and outputs of the rear blower motor relay include: - The common feed terminal (30) receives fused battery current at all times. - The coil ground terminal (85) is connected to a ground at all times. - The coil battery terminal (86) receives battery current from a fuse in the junction block (JB) through an ignition switch output (run) circuit only when the ignition switch is in RUN. - The normally open terminal (87) provides battery current output to the rear blower motor through the rear blower motor relay output circuit only when the rear blower motor relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the rear blower motor relay coil is de-energized. The rear blower motor relay cannot be adjusted or repaired and must be replaced if inoperative or damaged. See Wiring Information for diagnosis and testing of the rear blower motor relay and for complete HVAC wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair > Front Blower Motor Relay - Removal Blower Motor Relay: Service and Repair Front Blower Motor Relay - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Locate the power distribution center (PDC) (1). 3. Open the PDC cover (2). NOTE: Refer to the fuse and relay layout map on the inner surface of the PDC cover for rear blower motor relay identification and location. 4. Remove the rear blower motor relay (3) from the PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair > Front Blower Motor Relay - Removal > Page 188 Blower Motor Relay: Service and Repair Front Blower Motor Relay - Installation INSTALLATION NOTE: Refer to the fuse and relay layout map on the inner surface of the PDC cover for rear blower motor relay identification and location. 1. Position the rear blower motor relay (3) into the proper receptacle of the PDC (1). 2. Align the rear blower motor relay terminals with the terminal cavities in the PDC receptacle and push down firmly on the relay until the terminals are fully seated. 3. Close the PDC cover (2). 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair > Front Blower Motor Relay - Removal > Page 189 Blower Motor Relay: Service and Repair Rear Blower Motor Relay - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Locate the junction block (JB) (1) on the left side of the passenger compartment behind the cowl side trim panel. 3. Remove the rear blower motor relay (2) from the JB. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair > Front Blower Motor Relay - Removal > Page 190 Blower Motor Relay: Service and Repair Rear Blower Motor Relay - Installation INSTALLATION 1. Position the rear blower motor relay (2) into the proper receptacle of the junction block (JB) (1). 2. Align the rear blower motor relay terminals with the terminal cavities in the JB receptacle and push down firmly on the relay until the terminals are fully seated. 3. Reinstall the cowl side trim panel. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations A/C Clutch Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > A/C Clutch Relay - Description Compressor Clutch Relay: Description and Operation A/C Clutch Relay - Description DESCRIPTION The A/C clutch relay (1) is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The A/C clutch relay is located in the power distribution center (PDC) in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > A/C Clutch Relay - Description > Page 196 Compressor Clutch Relay: Description and Operation A/C Clutch Relay - Operation OPERATION The ISO-standard A/C clutch micro-relay is an electromechanical switch that uses a low current input controlled by the powertrain control module (PCM) to control the high current output to the A/C clutch field coil. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the A/C clutch field coil. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The A/C clutch relay terminals are connected to the vehicle electrical system through a receptacle in the power distribution center (PDC). The inputs and outputs of the A/C clutch relay include: - The common feed terminal (30) receives fused battery current at all times. - The coil ground terminal (85) receives a ground input from the PCM through the A/C clutch relay control circuit only when the PCM electronically pulls the control circuit to ground. - The coil battery terminal (86) receives fused battery current through a ignition switch output (run-start) circuit only when the ignition switch is in the On or Start positions. - The normally open terminal (87) provides a battery current output to the A/C clutch coil through the A/C clutch relay output circuit only when the compressor clutch relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the A/C clutch relay coil is de-energized. The A/C clutch relay cannot be adjusted or repaired and must be replaced if inoperative or damaged. See Wiring Information for diagnosis and testing of the A/C clutch relay and for complete HVAC wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Service and Repair > A/C Clutch Relay - Removal Compressor Clutch Relay: Service and Repair A/C Clutch Relay - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Locate the power distribution center (PDC) (1). 3. Open the PDC cover (2). NOTE: Refer to the fuse and relay map on the inside of the PDC cover for A/C clutch relay location. 4. Remove the A/C clutch relay (3) from the PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Service and Repair > A/C Clutch Relay - Removal > Page 199 Compressor Clutch Relay: Service and Repair A/C Clutch Relay - Installation INSTALLATION NOTE: Refer to the fuse and relay map on the inside of the PDC cover for A/C clutch relay location. 1. Position the A/C clutch relay (3) into the proper receptacle of the PDC (1). 2. Align the A/C clutch relay terminals with the terminal cavities in the PDC receptacle and push down firmly on the relay until the terminals are fully seated. 3. Close the PDC cover (2). 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C Does Not Cool Sufficiently/Evaporator Ices Up Control Module HVAC: Customer Interest A/C - Does Not Cool Sufficiently/Evaporator Ices Up NUMBER: 24-010-08 GROUP: Air Conditioning DATE: December 19, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.04 OR HIGHER. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: FLASH: Evaporator Freeze Up In A/C Equipped Vehicles OVERVIEW: This Bulletin involves reprogramming the Automatic Temperature Control module with new software. MODELS: 2009 (HB) Durango (HEV Only) 2009 (HG) Aspen(HEV Only) NOTE: This bulletin applies to vehicles equipped with HEV engine (sales code EZE) and Automatic Temperature Control (ATC) ATC (sales code HAF). SYMPTOM/CONDITION: Some customers may experience an intermittent condition where air flow from the HVAC vents is warmer than desired while driving with the HVAC system on. This may be due to evaporator freeze up. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) using the appropriate Diagnostic Procedures available in TechCONNECT, verify all ATC systems are functioning as designed. If DTC's are present record them on a repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is experienced or described by the customer, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 9.04 level software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C Does Not Cool Sufficiently/Evaporator Ices Up > Page 208 "DealerCONNECT > Service> StarSCAN(R) and StarMOBILE(R) tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old HVAC part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the HVAC in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash HVAC" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash HVAC" screen has updated to the new part number. NOTE: Due to the HVAC programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 7. Verify proper performance of HVAC system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C Does Not Cool Sufficiently/Evaporator Ices Up > Page 209 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up Control Module HVAC: All Technical Service Bulletins A/C - Does Not Cool Sufficiently/Evaporator Ices Up NUMBER: 24-010-08 GROUP: Air Conditioning DATE: December 19, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.04 OR HIGHER. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: FLASH: Evaporator Freeze Up In A/C Equipped Vehicles OVERVIEW: This Bulletin involves reprogramming the Automatic Temperature Control module with new software. MODELS: 2009 (HB) Durango (HEV Only) 2009 (HG) Aspen(HEV Only) NOTE: This bulletin applies to vehicles equipped with HEV engine (sales code EZE) and Automatic Temperature Control (ATC) ATC (sales code HAF). SYMPTOM/CONDITION: Some customers may experience an intermittent condition where air flow from the HVAC vents is warmer than desired while driving with the HVAC system on. This may be due to evaporator freeze up. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) using the appropriate Diagnostic Procedures available in TechCONNECT, verify all ATC systems are functioning as designed. If DTC's are present record them on a repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is experienced or described by the customer, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 9.04 level software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up > Page 215 "DealerCONNECT > Service> StarSCAN(R) and StarMOBILE(R) tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old HVAC part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the HVAC in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash HVAC" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash HVAC" screen has updated to the new part number. NOTE: Due to the HVAC programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 7. Verify proper performance of HVAC system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up > Page 216 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 217 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Front Blower Motor Power Module C1 (ATC) Control Module HVAC: Diagrams Front Blower Motor Power Module C1 (ATC) Connector C1 (ATC) MODULE-POWER-BLOWER MOTOR-FRONT (ATC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Front Blower Motor Power Module C1 (ATC) > Page 220 Control Module HVAC: Diagrams Front Blower Motor Power Module C2 (ATC) Connector C2 (ATC) MODULE-POWER-BLOWER MOTOR-FRONT (ATC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description Control Module HVAC: Description and Operation Front Blower Motor Power Module - Description DESCRIPTION A blower motor power module is used on this model when it is equipped with the automatic temperature control (ATC) heating-A/C system. Models equipped with the manual temperature control (MTC) heating-A/C system use a blower motor resistor block, instead of the blower motor power module . The blower motor power module is mounted to the rear of the HVAC housing, directly behind the glove box. The blower motor power module consists of a molded plastic mounting plate with two integral connector receptacles (1). Concealed behind the mounting plate is the power module electronic circuitry and a large finned heat sink (2). The blower motor power module is accessed for service from beneath the right side of the instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description > Page 223 Control Module HVAC: Description and Operation Front Blower Motor Power Module - Operation OPERATION The blower motor power module is connected to the vehicle electrical system through a dedicated lead and connector of the HVAC wire harness. A second connector receptacle receives the wire harness connector from the blower motor. The blower motor power module allows the microprocessor-based Automatic Temperature Control (ATC) A/C-heater control to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a Pulse Width Modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit that compares the PWM signal voltage to the blower motor feedback voltage. The resulting output drives the power module circuitry, which provides a linear output voltage to change or maintain the desired blower speed. The blower motor power module is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The blower motor power module cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal Control Module HVAC: Service and Repair Front Blower Motor Power Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: The heat sink for the blower motor power module may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor power module, wait five minutes to allow the heat sink to cool before performing diagnosis or service. Failure to take this precaution may result in possible serious injury. 1. Disconnect and isolate the negative battery cable. 2. If equipped with a trim cover (2), remove the two screws (1) that secure the trim cover over the blower motor power module (3) located below the right side of the instrument panel and remove the cover. 3. Disconnect the two wire harness connectors (1) from the blower motor power module (2). 4. Remove the two screws (3) that secure the blower motor power module to the front HVAC housing (4). 5. Remove the blower motor power module from the front HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal > Page 226 Control Module HVAC: Service and Repair Front Blower Motor Power Module - Installation INSTALLATION 1. Position the blower motor power module (2) into the front HVAC housing (4). 2. Install the two screws (3) that secure the blower motor power module to the front HVAC housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the two wire harness connectors (1) to the blower motor power module. 4. If equipped with a trim cover (2), install the trim cover over the blower motor power module (3) and install the two retaining screws (1). Tighten the screws to 2 Nm (17 in. lbs.). 5. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Locations > Page 231 Brake Lamp Relay: Diagrams Connector (IN PDC) RELAY-STOP LAMP ACTIVATION (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Description and Operation > Stop Lamp Inhibit Relay - Description Brake Lamp Relay: Description and Operation Stop Lamp Inhibit Relay - Description DESCRIPTION Vehicles equipped with an optional Electronic Stability Program (ESP)/Traction Control System (TCS) package have a stop lamp inhibit relay. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through four integral male spade-type terminals that extend from the relay base plate. The stop lamp inhibit relay is located in the Junction Block (JB) in the passenger compartment on the driver side cowl side inner panel below the end of the instrument panel. The stop lamp inhibit relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Description and Operation > Stop Lamp Inhibit Relay - Description > Page 234 Brake Lamp Relay: Description and Operation Stop Lamp Inhibit Relay - Operation OPERATION The stop lamp inhibit relay is an electromechanical switch that uses a low current input from the Controller Antilock Brake (CAB) to interrupt a high current output from the brake lamp switch to the brake lamps. Within the relay is an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the stop lamp inhibit relay include: - Common Supply Terminal (30) - The common feed terminal is connected to the output of the brake lamp switch at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a control output of the CAB through a stop lamp inhibit relay control circuit. The CAB controls brake lamp operation by controlling a ground path through this circuit. - Coil Battery Terminal (86) - The coil battery terminal is connected to a fused ignition switch output (run-start) circuit at all times. - Normally Closed Terminal (87A) - The normally closed terminal is connected to the brake lamps through a brake lamp switch output circuit and provides battery voltage to the brake lamps whenever the relay is de-energized. The stop lamp inhibit relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Fog Lamp Relay is located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 238 Fog/Driving Lamp Relay: Diagrams Connector (IN IPM) RELAY-FOG LAMP (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Description and Operation > Front Fog Lamp Relay - Description Fog/Driving Lamp Relay: Description and Operation Front Fog Lamp Relay - Description DESCRIPTION The front fog lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The front fog lamp relay is located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The front fog lamp relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Description and Operation > Front Fog Lamp Relay - Description > Page 241 Fog/Driving Lamp Relay: Description and Operation Front Fog Lamp Relay - Operation OPERATION The front fog lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to the front fog lamps. Within the relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the front fog lamp relay include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a fog lamp relay control circuit. The FCM controls front fog lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the front fog lamps through a fog lamp relay output circuit and provides battery voltage to the front fog lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The front fog lamp relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Horn Relay is located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 245 Horn Relay: Diagrams Connector (IN IPM) RELAY-HORN (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Park Lamp Relay Parking Lamp Relay: Locations Park Lamp Relay Park Lamp Relay is located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Park Lamp Relay > Page 250 Parking Lamp Relay: Locations Stop Lamp Inhibit Relay Stop Lamp Inhibit Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 251 Parking Lamp Relay: Diagrams Connector (IN IPM) RELAY-PARK LAMP (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Description and Operation > Parking Lamp Relay - Description Parking Lamp Relay: Description and Operation Parking Lamp Relay - Description DESCRIPTION The park lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The park lamp relay is located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The park lamp relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Description and Operation > Parking Lamp Relay - Description > Page 254 Parking Lamp Relay: Description and Operation Parking Lamp Relay - Operation OPERATION The park lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to the park lamps. Within the relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the park lamp relay include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a park lamp relay control circuit. The FCM controls park lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the park lamps through a park lamp relay output circuit and provides battery voltage to the park lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The park lamp relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Trailer Tow Left and Right Relays are located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Relay-Trailer Tow-Left Trailer Lighting Relay: Diagrams Relay-Trailer Tow-Left Connector (IN IPM) RELAY-TRAILER TOW-LEFT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Relay-Trailer Tow-Left > Page 260 Trailer Lighting Relay: Diagrams Relay-Trailer Tow-Right Connector (IN IPM) RELAY-TRAILER TOW-RIGHT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-014-09 > Sep > 09 > EVIC Module - Intermittent Or No Operation Power Distribution Module: Customer Interest EVIC Module - Intermittent Or No Operation NUMBER: 08-014-09 GROUP: Electrical DATE: September 3, 2009 SUBJECT: EVIC Module Intermittent or No Operation OVERVIEW: This bulletin involves inspecting the Satellite Antenna for looseness when making EVIC module repairs. MODELS: 2009 (HB) Durango (Includes Hybrid) 2009 (HG) Aspen (Includes Hybrid) SYMPTOM/CONDITION: The EVIC may intermittently operate or stop functioning. DISCUSSION: Before replacing the EVIC module, inspect the Satellite Antenna for looseness or for signs of water intrusion from around the antenna base. If looseness is found tighten the antenna before replacing the EVIC module. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-014-09 > Sep > 09 > EVIC Module - Intermittent Or No Operation Power Distribution Module: All Technical Service Bulletins EVIC Module - Intermittent Or No Operation NUMBER: 08-014-09 GROUP: Electrical DATE: September 3, 2009 SUBJECT: EVIC Module Intermittent or No Operation OVERVIEW: This bulletin involves inspecting the Satellite Antenna for looseness when making EVIC module repairs. MODELS: 2009 (HB) Durango (Includes Hybrid) 2009 (HG) Aspen (Includes Hybrid) SYMPTOM/CONDITION: The EVIC may intermittently operate or stop functioning. DISCUSSION: Before replacing the EVIC module, inspect the Satellite Antenna for looseness or for signs of water intrusion from around the antenna base. If looseness is found tighten the antenna before replacing the EVIC module. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center > Page 277 Power Distribution Module: Locations Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center > Page 278 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center > Page 279 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way Power Distribution Module: Diagrams 110v Inverter Module (Right Seat) 9 Way Connector - (RIGHT SEAT) 9 WAY MODULE-110V INVERTER - (RIGHT SEAT) 9 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 282 Power Distribution Module: Diagrams Integrated Power Module C1 (Headlamp And Dash) 40 Way Connector C1 - (HEADLAMP AND DASH) 40 WAY MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 283 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 284 Power Distribution Module: Diagrams Integrated Power Module C2 (Headlamp And Dash) 40 Way Connector C2 - (HEADLAMP AND DASH) 40 WAY MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 285 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 286 Power Distribution Module: Diagrams Integrated Power Module C3 (Battery) 1 Way Connector C3 - (BATTERY) 1 WAY MODULE-INTEGRATED POWER - (BATTERY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 287 Power Distribution Module: Diagrams 110v Inverter Module (Right Seat) 9 Way Connector - (RIGHT SEAT) 9 WAY MODULE-110V INVERTER - (RIGHT SEAT) 9 WAY Integrated Power Module C1 (Headlamp And Dash) 40 Way Connector C1 - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 288 MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 289 Integrated Power Module C2 (Headlamp And Dash) 40 Way Connector C2 - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 290 MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 291 Integrated Power Module C3 (Battery) 1 Way Connector C3 - (BATTERY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 292 MODULE-INTEGRATED POWER - (BATTERY) 1 WAY Power Distribution Center (Battery) 1 Way Connector (BATTERY) - 1 WAY POWER DISTRIBUTION CENTER (BATTERY) - 1 WAY Power Distribution Center C1 (Hard Wired) 20 Way Connector C1 - (HARD WIRED) 20 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 293 POWER DISTRIBUTION CENTER - (HARD WIRED) 20 WAY Power Distribution Center C2 (Hard Wired) 14 Way Connector C2 - (HARD WIRED) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 294 POWER DISTRIBUTION CENTER - (HARD WIRED) 14 WAY Power Distribution Center C3 (Hard Wired) 41 Way Connector C3 - (HARD WIRED) 41 WAY POWER DISTRIBUTION CENTER - (HARD WIRED) 41 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 295 Power Distribution Center C4 (Hard Wired) 15 Way Connector C4 - (HARD WIRED) 15 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 296 POWER DISTRIBUTION CENTER - (HARD WIRED) 15 WAY Power Distribution Center C5 (Hard Wired) 15 Way Connector C5 - (HARD WIRED) 15 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 297 POWER DISTRIBUTION CENTER - (HARD WIRED) 15 WAY Power Distribution Center C6 (HEV) (Hard Wired) 11 Way Connector C6 (HEV) - (HARD WIRED) 11 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 298 POWER DISTRIBUTION CENTER (HEV) - (HARD WIRED) 11 WAY Power Distribution Center C7 (HEV) (Hard Wired) 22 Way Connector C7 (HEV) - (HARD WIRED) 22 WAY POWER DISTRIBUTION CENTER (HEV) - (HARD WIRED) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 299 HEV Power Distribution Center (HEV) (In PDC) Connector (HEV) - (IN PDC) FUSE 2 (HEV) - (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module (IPM) - Description Power Distribution Module: Description and Operation Integrated Power Module (IPM) - Description DESCRIPTION The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The IPM is located in the engine compartment, next to the battery. The power distribution center mates directly with the (FCM) to form the IPM. The (PDC) is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module (IPM) - Description > Page 302 Power Distribution Module: Description and Operation Integrated Power Module (IPM) - Operation OPERATION All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal Power Distribution Module: Service and Repair Integrated Power Module (IPM) - Removal REMOVAL 1. Disconnect the negative and positive battery cables. 2. Unsnap cover and remove the B+ terminal nut from the integrated power module (IPM). Remove the B+ cable. 3. Remove the IPM from the retaining bracket (1). 4. Disconnect the connectors from the (IPM). 5. Remove the Front Control Module (FCM) (2) retaining screws. 6. Disconnect the front control module by pulling it straight off the integrated power module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal > Page 305 Power Distribution Module: Service and Repair Integrated Power Module (IPM) - Installation INSTALLATION 1. Install the Front Control Module (FCM) (2) to the Integrated Power Module (IPM). 2. Connect the electrical connectors to the IPM (1). 3. Install the IPM to the retaining bracket. 4. Install the B+ cable and nut on the IPM B+ terminal. Snap the cover in place. 5. Connect the negative and positive battery cables. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal > Page 306 Power Distribution Module: Service and Repair Power Inverter Module - Removal REMOVAL 1. Position the passenger front seat all the way back toward the rear of the vehicle. 2. Disconnect the power inverter electrical connector (1). 3. Remove the two mounting screws (2). 4. Position the front passenger seat all the way forward to gain access to the rear of the power inverter (2). 5. Remove the two rear mounting screws (1). 6. Remove the power inverter (2) by sliding it toward the driver seat. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal > Page 307 Power Distribution Module: Service and Repair Power Inverter Module - Installation INSTALLATION 1. Install the power inverter (2) by sliding it toward the passenger door. 2. Install the two rear mounting screws (1). 3. Position the passenger front seat all the way back toward the rear of the vehicle. 4. Install the two front mounting screws (2). 5. Connect the power inverter electrical connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) Relay Box: Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 312 Relay Box: Locations Remote Run Relay Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 313 Relay Box: Locations Run/Start Relay Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 314 Relay Box: Locations Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 315 Relay Box: Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Remote Run Relay Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 316 Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Run/Start Relay Run Remote Relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 317 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Junction Block Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay-Run Remote Relay Box: Diagrams Relay-Run Remote Connector (IN PDC) RELAY-RUN REMOTE (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay-Run Remote > Page 320 Relay Box: Diagrams Relay-Run/Start Connector (IN PDC) RELAY-RUN/START (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) Relay Box: Application and ID Hev Power Distribution Center (PDC) HEV Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 323 Relay Box: Application and ID Integrated Power Module Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 324 Relay Box: Application and ID Junction Block Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 325 Relay Box: Application and ID Power Distribution Center Power Distribution Center W/O HEV Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description Relay Box: Description and Operation Power Distribution Center (PDC) - Description DESCRIPTION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) is located next to the Power Distribution Center (PDC) (3) in the engine compartment. The HEV PDC (4) works with the Front Control Module (FCM) (1), the Integrated Power Module (IPM) (2) and the PDC (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 328 Relay Box: Description and Operation Power Distribution Center (PDC) - Operation OPERATION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) provides the extra power needed for the Hybrid Electric Vehicle (HEV). The HEV PDC provides power to: - Transmission Auxiliary Pump (TPCM) - Electric Vacuum Pump - Electric High Voltage Power Steering (EHPS) - Solid State Relay Electric Vacuum Pump The HEV PDC is serviced as part of the engine compartment body harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 329 Relay Box: Description and Operation Junction Block - Description DESCRIPTION An electrical Junction Block (JB) (1) is concealed behind the left outboard end of the instrument panel cover. The JB combines the functions previously provided by a separate fuseblock module and relay center, serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as a fuse layout to help ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 330 Relay Box: Description and Operation Junction Block - Operation OPERATION All of the circuits entering and leaving the JB do so through wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal Relay Box: Service and Repair Power Distribution Center (PDC) - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Depress retaining tabs on the side on the PDC (1). 3. Disconnect electrical harness connectors (2) and remove PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 333 Relay Box: Service and Repair Power Distribution Center (PDC) - Installation INSTALLATION 1. Connect electrical harness connectors to Power Distribution Center (PDC). 2. Position PDC and engage into the retaining tabs. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 334 Relay Box: Service and Repair Junction Block - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left cowl trim cover. 3. Remove the mounting fasteners (3). 4. Disconnect the electrical harness connectors and remove Junction Block (1). 5. Transfer components as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 335 Relay Box: Service and Repair Junction Block - Installation INSTALLATION 1. Connect wire harness connectors to the Junction Block (JB) (1). 2. Position JB and install mounting fasteners (3). 3. Install left cowl trim cover. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Front Control Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Front Control Module > Page 342 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way Body Control Module: Diagrams Front Control Module (PDC AUX) 49 Way Connector - (PDC AUX) 49 WAY MODULE-FRONT CONTROL - (PDC AUX) 49 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 345 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 346 Body Control Module: Diagrams Front Control Module C1 (Headlamp And Dash) 24 Way Connector C1 - (HEADLAMP AND DASH) 24 WAY MODULE-FRONT CONTROL - (HEADLAMP AND DASH) 24 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 347 Body Control Module: Diagrams Front Control Module C2 (Headlamp And Dash) 12 Way Connector C2 - (HEADLAMP AND DASH) 12 WAY MODULE-FRONT CONTROL - (HEADLAMP AND DASH) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 348 Body Control Module: Diagrams Hybrid Gateway Module C1 (HEV) (Headlamp And Dash) 24 Way Connector C1 (HEV) - (HEADLAMP AND DASH) 24 WAY MODULE-HYBRID GATEWAY (HEV) - (HEADLAMP AND DASH) 24 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 349 Body Control Module: Diagrams Hybrid Gateway Module C2 (HEV) (Headlamp And Dash) 12 Way Connector C2 (HEV) - (HEADLAMP AND DASH) 12 WAY MODULE-HYBRID GATEWAY (HEV) - (HEADLAMP AND DASH) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description Body Control Module: Description and Operation Gateway Module - Description DESCRIPTION Vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system have a Hybrid Gateway Module (HGM) (1) that is secured with three screws to the stamped steel Transmission Auxiliary Oil Pump (TAOP) control module mounting bracket located on the left hydro form (frame rail) near the back of the left front wheel housing within the engine compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum HGM housing is the electronic circuitry of the HGM, which includes a microprocessor and an electronic printed circuit board. A stamped metal cover plate (2) is sealed and secured to the HGM housing with four screws to enclose and protect the internal electronic circuitry and components. Two molded plastic electrical connectors (3), one containing 24 terminal pins and the other containing 12 terminal pins, exit the forward facing side of the HGM cover plate and are pointed downward. These terminal pins connect the HGM to the vehicle electrical system through two dedicated take outs and connectors of the headlamp and dash wire harness. The HGM housing has integral mounting flanges on two sides with three mounting holes in each flange. The mounting flange to the left of the connector receptacles is secured to the TAOP control module mounting bracket with two screws, while the flange on the right side is secured to the bracket with only one screw. The HGM cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description > Page 352 Body Control Module: Description and Operation Front Control Module - Description DESCRIPTION The Front Control Module (FCM) is a micro controller based module located in the left front corner of the engine compartment. The front control module mates to the power distribution center to form the Integrated Power Module (IPM). The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The front control module controls power to some of these vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the CAN bus circuit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description > Page 353 Body Control Module: Description and Operation Front Control Module - Operation OPERATION As messages are sent over the CAN bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are controlled by the FCM: - Front turn signals - Stop, turn signal and tail lamps - Front and rear hazard warning lamps - Headlamps - Fog Lamps - Daytime running lamps - if equipped - Horn - Windshield and liftgate wiper and washer systems - Transfer case shifting - Trailer tow wiring output - Rear window defroster power and timing - Air conditioning condenser cooling fan The FCM provides the following features for the above function: - It provides a illuminated approach feature that turns the headlamps on when the vehicle is unlocked with the Remote Keyless Entry (RKE) transmitter. - It flashes lamps in response to turn signal, RKE and Vehicle Theft Security System (VTSS) inputs. - It sounds the horn in response to RKE and VTSS inputs. - It turns off the horn in the event of excessively long operation that could otherwise damage the horn. - It turns off the windshield washer motor after 10 seconds of continuous operation to protect the motor. - It minimizes voltage variations to the headlamps to extend bulb life and to equalize the light output from the lamps, which might otherwise differ due to variations in wiring resistance. - If the headlamps are left on, it automatically turns them off after eight minutes to protect the battery from discharge.It monitors battery voltage and turns off non-essential functions such as the fog lamps, rear window defogger, and heated seats if necessary to conserve battery power. - It operates the high-beam headlamps at reduced intensity by pulse-width modulation of the power supply to provide the daytime running lamps. - It provides the variable delay intermittent windshield and liftgate wiper time delay features, and the vehicle speed sensitive windshield wiper delay variation. - It acts as a link between the CAN bus network for critical powertrain and anti-lock brake systems and the network for body and interior modules. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description > Page 354 Body Control Module: Description and Operation Gateway Module - Operation OPERATION The Hybrid Gateway Module (HGM) provides a communication interface between the electronic control modules (nodes) in the vehicle, as well as with the diagnostic scan tool connected to the Controller Area Network (CAN) data bus system and the nodes connected to the Hybrid Local Area Network (H-LAN) data bus system. The HGM is the central gateway that processes and transfers messages between the different bus systems. In addition, the HGM is Local Interface Network (LIN) bus compatible. It receives a direct input over the LIN bus from a humidity sensor secured to the inside rear view mirror mount on the inside of the windshield glass, which it then transmits over the CAN data bus to other electronic modules in the vehicle. The microprocessor-based HGM also provides input and output circuitry that responds to both digital and analog inputs and provides electronically controlled higher current load outputs through lower current relay drivers. The HGM uses On-Board Diagnostics (OBD). If the HGM detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) that can be retrieved with a diagnostic scan tool through the 16-way data link connector located on the driver side lower edge of the instrument panel. The HGM connects directly to a fused battery current input and to ground, so that it remains capable of operating, regardless of the ignition switch position. The hardwired inputs and outputs for the HGM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the HGM, the electronic controls or communication between other modules and devices that provide features of the Hybrid Electric Vehicle (HEV) control system. The most reliable, efficient and accurate means to diagnose the HGM, the electronic controls and communication related to HGM operation, requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Front Control Module (FCM) Intermittent Condition Test Body Control Module: Testing and Inspection Front Control Module (FCM) Intermittent Condition Test INTERMITTENT CONDITION For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. INTERMITTENT CONDITION NOTE: The conditions that set the DTC are not present at this time. The following list may help in identifying the intermittent condition. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 1. Perform any Technical Service Bulletins (TSBs) that may apply. 2. Review the scan tool Freeze Frame information. If possible, try to duplicate the conditions under which the DTC set. 3. Turn the ignition off. 4. Visually inspect the related wire harness. Wiggle the related wire harness and look for an interrupted signal on the affected circuit. Disconnect all the related harness connectors. Look for any chafed, pierced, pinched, partially broken wires and broken, bent, pushed out, or corroded terminals. 5. Perform a voltage drop test on the related circuits between the suspected inoperative component and the Anti-Lock Brake Module, Front Control Module, or Totally Integrated Power Module, which every applies to the circuits in questions. 6. Inspect and clean all Powertrain Control Module (PCM), APS, engine, and chassis grounds that are related to the most current DTC. 7. If numerous trouble codes were set, use a wire schematic and look for any common ground or supply circuits 8. For any Relay DTCs, actuate the Relay with the scan tool and wiggle the related wire harness to try to interrupt the actuation. 9. Use the scan tool to perform a System Test if one applies to failing component. 10. A co-pilot, data recorder, and/or lab scope should be used to help diagnose intermittent conditions. Were any problems found during the above inspections? Yes - Perform the necessary repairs. - Perform the APS VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/APS Verification Test. No - Test Complete. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Front Control Module (FCM) Intermittent Condition Test > Page 357 Body Control Module: Testing and Inspection Wireless Control Module (WCM) Intermittent Condition Test WIRELESS CONTROL MODULE (WCM) INTERMITTENT TEST For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. RECORD AND ERASE ALL WCM DIAGNOSTIC TROUBLE CODES (DTCS) Using a scan tool, record and erase all DTCs from the WCM. Monitor any active codes as you work through the following steps. - Review the code monitor and set conditions for any DTCs that are stored and attempt to reproduce the conditions listed. - Wiggle the wiring harness and connectors of the related circuit, sensor or component. - Turn the ignition off. Search for any Technical Service Bulletins (TSBs) that may apply. Was the source of the customer complaint found or did any DTCs appear and stay active? Yes - Make the appropriate repairs and perform the WIRELESS CONTROL MODULE (WCM) VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Wireless Control Module (WCM) Verification Test or select the correct DTC procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. No - Go To 2 2. ATTEMPT TO REPRODUCE THE CONDITION In the event the customer complaint cannot be duplicated due to an intermittent condition in the theft/security system, the following may aid in attempting to reproduce the condition. - Using the wiring diagram/schematic as a guide, inspect the wiring and connectors related to the stored code or component in question. - Look for chafed, pierced, pinched, or partially broken wires and broken, bent, pushed out, spread, corroded, or contaminated terminals. - If the customer concern was related to a specific fobik, ensure the fobik in question is used while attempting reproduce the condition. - Reconnect any disconnected components and harness connectors and ensure they are properly seated. - If numerous trouble codes were set, use a schematic and inspect any common ground or supply circuits. Was the source of the intermittent condition located? Yes - Make the appropriate repairs and perform the WIRELESS CONTROL MODULE (WCM) VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Wireless Control Module (WCM) Verification Test No - The problem cannot be found at this time. If repeated intermittent failures are encountered that cannot be reproduced and the condition has prompted multiple customer visits to the dealership, document any findings on the repair order. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Front Control Module (FCM) Intermittent Condition Test > Page 358 Body Control Module: Testing and Inspection Wireless Control Module (WCM) Pre-Diagnostic Procedure WIRELESS CONTROL MODULE (WCM) PRE-DIAGNOSTIC PROCEDURE Before attempting to repair any theft or security system, technicians should be familiar with and fully understand the system operation. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Description and Operation/Vehicle Theft Security System - Description. The following should be used as a checklist to be completed in its entirety prior to referencing specific Theft and Security Diagnostic Procedures. FOLLOW THE BASIC OUTLINE IN THE SIX-STEP TROUBLESHOOTING PROCEDURE - Verification of complaint - Verification of any related symptoms - Symptom analysis - Problem isolation - Repair of isolated problem - Verification of proper operation TAKE INTO ACCOUNT CURRENT VEHICLE CONDITION, REPAIR HISTORY, AND TECHNICAL SERVICE BULLETINS (TSBs) - Verify there are no outward signs of vehicle damage that could impact the proper operation of the theft or security system. Check for aftermarket vehicle accessories that may have been installed improperly or could interfere with the system - Check the vehicle repair history for repairs that may relate to the current condition. - Perform a check of current Technical Service Bulletins (TSB) for the system related to the customer concern. If a TSB applies, follow the procedure outlined in the TSB. DIAGNOSE ONLY THOSE FAILURES THAT ARE ACTIVE AND CAN BE REPRODUCED - Check the control module central to the subsystem that is exhibiting the condition for active Diagnostic Trouble Codes (DTCs). - For an intermittent failure that is not current at the time of vehicle inspection, refer to the WIRELESS CONTROL MODULE INTERMITTENT TEST See: Wireless Control Module (WCM) Intermittent Condition Test and document the event on the repair order. ADDRESS ACTIVE DTCS IN THE CORRECT ORDER - Low/High Voltage and Serial Data Loss of Communication Codes - Module Internal Failure and Configuration Mismatch Codes - Circuit specific DTC failures As a general rule, for any theft/security system control module that exhibits more than one active DTC, address the codes in the order indicated; should the malfunction still be present after conducting this Pre-diagnostic Procedure, technicians should continue to the appropriate DTC procedure or symptom diagnostic. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal Body Control Module: Service and Repair Gateway Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. A technician trained in proper Hybrid Electric Vehicle (HEV) service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. Unlatch and remove the Power Distribution Center (PDC) from the PDC mounting bracket on the left hydro form (frame rail) over the left front wheel house in the engine compartment. Move the PDC forward far enough to access the Hybrid Gateway Module (HGM) (1). 3. Remove the three screws (2) that secure the HGM to the Transmission Auxiliary Oil Pump (TAOP) control module mounting bracket (3) that is secured to the left hydro form near the back of the left front wheel house. 4. Disconnect the two headlamp and dash wire harness connectors (4) from the HGM connector receptacles located on the forward facing side of the module. 5. Remove the HGM from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal > Page 361 Body Control Module: Service and Repair Gateway Module - Installation INSTALLATION 1. Position the Hybrid Gateway Module (HGM) (1) near the Transmission Auxiliary Oil Pump (TAOP) control module mounting bracket (3) that is secured to the left hydro form (frame rail) near the back of the left front wheel house in the engine compartment. 2. Reconnect the two headlamp and dash wire harness connectors (4) to the HGM connector receptacles located on the forward facing side of the module. 3. Position the HGM to the TAOP control module mounting bracket. 4. Install and tighten the three screws (2) that secure the HGM to the mounting bracket. Tighten the screws securely. 5. Reinstall the Power Distribution Center (PDC) onto the PDC mounting bracket on the left hydro form over the left front wheel house in the engine compartment. Be certain that each of the PDC latches is fully engaged with the mounting bracket. 6. Reconnect the battery negative cable. A technician trained in proper Hybrid Electric Vehicle (HEV) service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal > Page 362 Body Control Module: Service and Repair Front Control Module - Removal REMOVAL 1. Disconnect the positive and negative battery cables from the battery. 2. Partially remove the Integrated Power Module (IPM) from the engine compartment. 3. Remove the front control module retaining screws. 4. Pull the front control module straight from the IPM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal > Page 363 Body Control Module: Service and Repair Front Control Module - Installation INSTALLATION 1. Press the Front Control Module (FCM) onto the Integrated Power Module (IPM). 2. Install the mounting fasteners. 3. Install the IPM. 4. Connect the positive and negative battery cables. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 367 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way Engine Control Module: Diagrams Powertrain Control Module C1 38 Way Connector C1 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 370 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 371 Engine Control Module: Diagrams Powertrain Control Module C2 38 Way Connector C2 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 372 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 373 Engine Control Module: Diagrams Powertrain Control Module C3 38 Way Connector C3 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 374 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 375 Engine Control Module: Diagrams Powertrain Control Module C4 38 Way Connector C4 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 376 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description Engine Control Module: Description and Operation Powertrain Control Module - Description PCM POWERTRAIN CONTROL MODULE (PCM) The PCM (2) is attached to the right-front inner fender (1) located in the engine compartment. Modes of Operation MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 379 - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The O2S sensor heater element is energized via the ASD relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Starter motor relay - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the clutch relay. This is done if A/C has been selected by the vehicle operator and requested by the A/C thermostat. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 380 - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 381 If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5V Power Supplies 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Ignition Circuit Sense IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Powertrain Control Module (PCM). Battery voltage is supplied to the PCM through the ignition switch when the ignition is in the Run or Start position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Power Grounds POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Sensor Return SENSOR RETURN Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 382 The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. For more information, See: . Signal Ground SIGNAL GROUND Signal ground provides a low noise ground to the data link connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 383 Engine Control Module: Description and Operation Powertrain Control Module - Operation PCM POWERTRAIN CONTROL MODULE (PCM) The PCM is a pre-programmed, microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - Accelerator pedal position sensor (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CAN bus (+) circuits - CAN bus (-) circuits - Camshaft position sensor signal - Clutch Interlock Switch (if equipped) - Crankshaft position sensor - Data link connection for diagnostic scan tool - EGR position sensor (if equipped) - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensor(s) (if equipped) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure sensor - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission output speed sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 384 NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - CAN bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for diagnostic scan tool - Double start override (if equipped) - EGR valve control solenoid (if equipped) - Electronic throttle control - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle air control (IAC) motor - Ignition coil(s) - CAN bus circuits - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CAN bus circuits. - Overdrive indicator lamp (if equipped) - Radiator cooling fan (if equipped) - Speed control vacuum solenoid - Speed control vent solenoid - Starter relay - Tachometer (if equipped). Driven through CAN bus circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid 5V Power Supplies 5 VOLT SUPPLIES Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (if equipped with an RE automatic transmission). Ignition Circuit Sense IGNITION CIRCUIT SENSE The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 385 Engine Control Module: Testing and Inspection CHECKING THE PCM POWER AND GROUND CIRCUITS For a complete wiring diagram refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. PCM WIRING OR CONNECTORS 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and each connector at the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. No - Go To 2 2. CHECKING THE PCM GROUND CIRCUITS 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to 12 volts, check the PCM ground circuits. 3. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go To 3. No - Repair the PCM ground circuit(s) for an open circuit or high resistance. - Perform the POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 386 3. CHECKING THE PCM FUSED IGNITION CIRCUITS CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 1. Turn the ignition on. 2. Using a 12 volt test light connected to ground, check the PCM Fused Ignition circuits. 3. Check each circuit with the ignition on, engine running position, and during cranking. 4. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go To 4. No - Repair the open or short to ground in the PCM Fused Ignition circuits. - Perform the POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. 4. CHECKING THE PCM FUSED B+ CIRCUITS 1. Turn the ignition off. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 387 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to Ground, check the PCM Fused B+ circuits. 3. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright with the ignition on and not illuminated with the ignition off. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated as described above? Yes - Test complete. No - Repair the open or short to ground in the PCM Fused B+ circuit(s) for as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Resolver Learn STANDARD PROCEDURE - RESOLVER LEARN RESOLVER OFFSET LEARN TRIGGER EVT AHS-T TRANSMISSION The Resolver Offset Learn Trigger Procedure requires the use of a scan tool. This program allows the electronic variable transmission (EVT) AHS-T to re-calibrate itself. This will provide the proper transmission operation. The resolver offset learn procedure should be performed if any of the following procedures are performed: - Transmission Assembly Replacement - Transmission Electronic Hydraulic Control Module (TEHCM) Replacement - Flashing the TCM - Electric Motors Replacement - Valve Body Replacement or Recondition To perform the Resolver Offset Learn Trigger Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The shift lever position must stay in PARK until prompted to shift. - The calculated oil temperature must be above 15° C (60° F) and below 93° C (200° F) TCM Quick Learn QUICK LEARN TCM QUICK LEARN RFE and RLE The quick learn procedure requires the use of a scan tool. This program allows the electronic transmission system to re-calibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: - Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool indicates the procedure is complete - The calculated oil temperature must be above 15° C (60° F) and below 93° C (200° F) TCM Drive Learn DRIVE LEARN RFE and RLE When a transmission is repaired and a Quick Learn procedure has been performed on the Transmission Control Module (TCM), the following Drive Learn procedure can be performed to fine tune any shifts which are particularly objectionable. NOTE: It is not necessary to perform the complete Drive Learn procedure every time the TCM is Quick Learned. Perform only the portions which target the objectionable shift. LEARN A SMOOTH 1ST NEUTRAL TO DRIVE SHIFT Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 390 Perform this procedure only if the complaint is for a delayed or harsh shift the first time the transmission is put into gear after the vehicle is allowed to set with the engine not running for at least 10 minutes. Use the following steps to have the TCM learn the 1st N-D UD CVI. NOTE: The transmission oil temperature must be between 27-43° C (80-110° F). 1. Start the engine only when the engine and ignition have been off for at least ten (10) minutes. 2. With the vehicle at a stop and the service brake applied, record the 1st N-D UD CVI while performing a Neutral to Drive shift. The 1st N-D UD CVI accounts for air entrapment in the UD clutch that may occur after the engine has been off for a period of time. 3. Repeat 1 and 2 until the recorded 1st N-D UD CVI value stabilizes. NOTE: It is important that this procedure be performed when the transmission temperature is between 27-43° C (80-110° F). If this procedure takes too long to complete fully for the allowed transmission oil temperature, the vehicle may be returned to the customer with an explanation that the shift will improve daily during normal vehicle usage. The TCM also learns at higher oil temperatures, but these values (line pressure correction values) are not available for viewing on the scan tool. LEARN A SMOOTH NEUTRAL TO DRIVE GARAGE SHIFT Perform this procedure if the complaint is for a delayed or harsh shift when the transmission is put into gear after the vehicle has had its first shift. Use the following steps to have the TCM learn the Norm N-D UD CVI. NOTE: The transmission oil temperature must be between 27-43° C (80-110° F) to learn the UD CVI. Additional learning occurs at temperatures as low as -18° C (0° F) and as high as 93° C (200° F). This procedure may be performed at any temperature that experiences poor shift quality. Although the UD CVI may not change, shift quality should improve. 1. Start the vehicle engine and shift to drive. 2. Move the vehicle forward to a speed of at least 16 km/h (10 MPH) and come to a stop. This ensures no air is present in the UD hydraulic circuit. 3. Perform repeated N-D shifts at a stop while pausing in Neutral for at least 2-3 seconds and monitor Norm N-D UD CVI volume until the value stabilizes. The value will change during the N-D shift. This is normal since the UD value is different for the N-D shift then the normal value shown which is used for 4-3 coastdown and kick downs. Perform repeated shifts in this temperature range until the Norm N-D UD CVI value stabilizes and the N-D shifts become smooth. LEARN THE 1ST 2-3 SHIFT AFTER A RESTART OR SHIFT TO REVERSE Use the following steps to have the TCM learn the 1st 2-3 shift OD CVI. NOTE: The transmission oil temperature must be above 27° C (80° F). 1. With the vehicle engine running, select reverse gear for over 2 seconds. 2. Shift the transmission to Drive and accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform a 2-3 shift while noting the 1st 2-3 OD CVI. 3. Repeat 1 and 2 until the 1st 2-3 upshift becomes smooth and the 1st 2-3 OD CVI stabilizes. LEARN A SMOOTH 2-3 AND 3-4 UPSHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the OD and 4C CVI's. 1. Accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform multiple 1-2, 2-3, and 3-4 upshifts. The 2nd 2-3 shift following a restart or shift to reverse will be shown during the shift as a value between the 1st 2-3 OD CVI and the normal OD CVI. Updates to the normal OD CVI will occur after the 2nd shift into 3rd gear, following a restart or shift to reverse. 2. Repeat 1 until the 2-3 and 3-4 shifts become smooth and the OD and 4C CVI become stable. LEARN A SMOOTH 4-3 COASTDOWN AND PART THROTTLE 4-3 KICKDOWN NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the UD shift volume. 1. At a vehicle speed between 64-97 km/h (40-60 MPH), perform repeated 4-3 kickdown shifts. 2. Repeat 1 until the UD volume becomes somewhat stable and the shift becomes smooth. LEARN A SMOOTH 1-2 UPSHIFT AND 3-2 KICKDOWN Use the following steps to have the TCM learn the 2C shift volume. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 391 NOTE: The transmission oil temperature must be above 43° C (110° F). 1. With a vehicle speed below 48 km/h (30 MPH) and the transmission in 3rd gear, perform multiple 3-2 kick downs. 2. Repeat 1 until the 3-2 kick downs become smooth and the 2C CVI becomes stable. LEARN A SMOOTH MANUAL 2-1 PULLDOWN SHIFT AS WELL AS A NEUTRAL TO REVERSE SHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the LR volume. 1. With the vehicle speed around 40-48 km/h (25-30 MPH) in Manual 2nd, perform manual pulldowns to Low or 1st gear at closed throttle. 2. Repeat 1 until the LR CVI becomes stable and the manual 2-1 becomes smooth. LEARN A SMOOTH NEUTRAL TO REVERSE SHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). 1. With the vehicle at a stop, perform Neutral to Reverse shifts until the shift is smooth. An unlearned Neutral to Reverse shift may be harsh or exhibit a double bump. 2. If any of the shifts are still not smooth after the clutch volume stabilizes, an internal transmission problem may be present. LEARN A SMOOTH 4-5 UPSHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the Alt 2C CVI. 1. Accelerate the vehicle through 88 km/h (55 mph) at a steady 10-15 degree throttle opening and perform multiple 4-5 upshifts. 2. Repeat 1 until the 4-5 shift become smooth and the Alt 2C CVI become stable. There is a separate 2C volume used and learned for 4-5 shifts, 2CA. It is independent of the 2C CVI learned on 3-2 kick downs. PCM/ECM Reprogramming PCM/ECM REPROGRAMMING - GAS PCM / TCM FLASH REPROGRAMING This procedure will need to be done when one or more of the following situations are true: 1. A vehicle's Powertrain control module (PCM) has been replaced. 2. A diagnostic trouble code (DTC) is set "P1602 - PCM Not Programmed." 3. An updated calibration or software release is available for either the PCM or TCM ECUs. This procedure assumes that the StarSCAN(R) and StarMOBILE(R) devices are configured to your dealership's network with either a wired or wireless connection. The StarSCAN(R) and StarMOBILE(R) must also be running at the latest operating system and software release level. For more help on how to network your StarSCAN(R) or StarMOBILE(R) reference the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation' under the Download Center. Table of contents 1. SECTION 1 - PCM / TCM FLASH PROCEDURE SECTION 1 - PCM / TCM FLASH PROCEDURE 2. REQUIRED TOOLS/EQUIPMENT REQUIRED TOOLS/EQUIPMENT: 3. TECH TIPS and INFORMATIONTECH TIPS and INFORMATION: 4. PARTS REQUIRED PARTS REQUIRED SECTION 1 - PCM / TCM FLASH PROCEDURE If using StarSCAN(R) or StarMOBILE(R) Desktop Client. Go to REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client If using StarMOBILE(R) Stand-alone Diagnostic Mode. Go To REPAIR PROCEDURE - Using StarMOBILE(R) Stand-alone Diagnostic Mode REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 392 NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the StarSCAN(R) or StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power on the StarSCAN(R) or StarMOBILE(R). If the StarMOBILE(R) is being used, launch the StarMOBILE(R) Desktop Client and connect to the appropriate StarMOBILE(R) device. 4. Retrieve the old ECU part number. From the tool's Home screen, a. Select "ECU View" b. Select "PCM" c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the Flash PCM screen for later reference. 5. Program the ECU as follows: a. Using the StarSCAN(R) / StarMOBILE(R) at the Home screen, select "ECU View" b. Select "PCM" c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File" and follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 4e, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. g. Select "Download to Scantool" h. Once the download is complete, select "Close" and then "Back" i. Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. j. When the PCM update is complete, select "OK" k. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 6. Continue to SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 7. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See Section 3 SECTION 3 - AUTHORIZED MODIFICATION LABEL for details). REPAIR PROCEDURE - Using StarMOBILE(R) Stand-alone Diagnostic Mode NOTE: StarMOBILE(R) Stand-alone Mode is an efficient way to flash ECUs without having direct access to a network connection. It involves first copying the flash file to the StarMOBILE(R) device which DOES require a network connection. Once the file has been copied to the StarMOBILE(R) device, it can be used in a Stand-alone mode to flash the ECU WITHOUT a network connection. NOTE: StarMOBILE(R) does not need to be connected to a vehicle when retrieving a flash file for Stand-alone Mode. 1. Power on the StarMOBILE(R). Launch the StarMOBILE(R) Desktop Client and connect to the tool. 2. At the Home screen, select "ECU View" a. Select "PCM" b. Select "More Options" c. Select "ECU Flash" d. Select "Browse for New File" and follow the on screen instructions. e. Highlight the appropriate calibration based on the current ECU part number, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. 3. From the Flash File List, select the appropriate calibration for the PCM and select "Download to Client" 4. Once the download is complete, hit "OK" and then "Manage Files" Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 393 5. In the Manage Files screen, highlight the downloaded flash file and select "Copy to SM Device". A green check mark should now appear in the On SM Device column. 6. Exit the StarMOBILE(R) Desktop Client application. 7. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 8. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 9. On the StarMOBILE(R) device, select "Enter Stand-alone Diagnostic Mode" (use the right function key). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 394 NOTE: If a StarMOBILE(R) Desktop Client is still associated with the device, you will receive the following error: "Your StarMOBILE(R) device is currently locked by a pc named 'xxxxxxxx' on your network. To remove the lock, close its Desktop Client or reboot this device". 10. Program the ECU as follows: a. Select "ECU View" b. Select "PCM" c. Select "Flash ECU" d. Record the ECU part number at the very top of the screen for later reference. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 395 e. Highlight the flash file that you want to use. Hit "SELECT" and then "OK". Follow the on screen instructions. f. Once the flash is complete, verify that the part number at the top of the Flash PCM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 11. Continue to Section 2SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 12. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See Section 3 SECTION 3 - AUTHORIZED MODIFICATION LABEL for details). SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES Find the PCM/TCM Type for the vehicle, read and write down the steps, and then go to the step by step instructions for additional information on how to perform these procedures. STEP-BY-STEP INSTRUCTIONS If a NGC3 or NGC4 PCM was replaced, perform the following additional steps and/or routines: 1. PCM Replaced - if WCM equipped 2. Learn ETC - if ETC equipped 3. Check PCM Odometer 4. Check PCM VIN - if NOT WCM equipped 5. Quicklearn - if EATX equipped If a GPEC PCM was replaced, perform the following additional steps and/or routines: 1. If the vehicle is equipped with a CVT, ensure that the TCM has the latest software calibration available (if the vehicle is not equipped with a CVT, skip to Step 3). 2. PCM Replaced - if WCM equipped Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 396 3. Learn ETC 4. Check PCM Odometer 5. Check PCM VIN - if NOT WCM equipped 6. TCM Quicklearn - if EATX equipped If a CVT TCM was replaced, perform the following additional steps and/or routines: 1. Initialize CVT If an EGS TCM was replaced, perform the following additional steps and/or routines: 1. Initialize EGS STEP-BY-STEP INSTRUCTIONS Check PCM Odometer From the "Home" screen, select "ECU View". - Select "PCM" - Select "Misc. Functions" - Select "Check PCM Odometer" and follow the on screen instructions. - When complete, select "Finish". Check PCM VIN From the "Home" screen, select "ECU View" - Select "PCM" - Select "Misc. Functions" - Select "Check PCM VIN" and follow the on screen instructions. - When complete, select "Finish" Initialize CVT From the "Home" screen, select "ECU View" - Select "TCM" - Select "Misc. Functions" - Select "Initialize CVT" and follow the on screen instructions. - When complete, select "Finish" Initialize EGS From the "Home" screen, select "ECU View" - Select "TCM" - Select "Misc. Functions" - Select "Initialize EGS" and follow the on screen instructions. - When complete, select "Finish" Learn ETC From the "Home" screen, select "ECU View" - Select "PCM" - Select "Misc. Functions" - Select "Learn ETC" and follow the on screen instructions. - When complete, select "Finish" PCM Replaced The vehicle pin (Personal Identification Number) will be required to complete the routine. This information may be obtained in three ways: 1. The original selling invoice 2. Dealer CONNECT > Parts > Key Codes Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 397 3. Contacting the District Manager. From the "Home" screen, select "ECU View" - Select "WCM" - Select "Misc. Functions" - Select "PCM Replaced" and follow the on screen instructions. - When complete, select "Finish" Quicklearn From the "Home" screen, select "ECU View" - Select "PCM" - Select "Misc. Functions" - Select "Quicklearn" and follow the on screen instructions. - When complete, select "Finish" Update CVT TCM From the "Home" screen: - Select "ECU View" - Select "TCM" - Select "More Options" - Select "ECU Flash" - Select "Browse for New File" and follow the on screen instructions. - Highlight the appropriate calibration. - Select "Download to Scantool" - Once the download is complete, select "Close" and then "Back" - Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. - When the TCM update is complete, select "OK" - Verify that the part number at the top of the "Flash TCM" screen has updated to the latest level. SECTION 3 - AUTHORIZED MODIFICATION LABEL NOTE: The following step is required by law when reprogramming a PCM and/or TCM. Type the necessary information on the "Authorized Modification Label" and attach near the VECI label. 1. Powertrain Control / Transmission Control Module Part Numbers (Insert P/Ns) Used 2. Change Authority: TSB XX--XX 3. Dealer Code: XXXXX 4. Date: XX-XX-XX REQUIRED TOOLS/EQUIPMENT: TECH TIPS and INFORMATION: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 398 1. StarMOBILE(R) Stand-alone Diagnostic Mode is an efficient way to flash ECUs without having direct access to a network connection. It involves first copying the flash file to the StarMOBILE(R) device which DOES require a network connection. Once the file has been copied to the StarMOBILE(R) device, it can be used in a Stand-alone mode to flash the ECU WITHOUT a network connection. 2. To use the StarMOBILE(R) in Pass-Through Mode requires that your StarMOBILE(R) is connected to the dealerships network via a wired or wireless connection. For more information on how to use the StarMOBILE in Pass-Through Mode see the StarMOBILE(R) training tutorials available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Training Aids' link under the 'Training Aids' link. 3. StarMOBILE(R) does not need to be connected to a vehicle when retrieving a flash file for Stand-alone Mode. 4. Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The ECU can only be reprogrammed to a more recent version of that calibration. 5. If the flash process is interrupted or aborted, the flash should be restarted. 6. Due to the PCM / TCM programming procedure, a DTC may be set in other ECUs within the vehicle. Some DTCs may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 7. When replacing a GPEC PCM for a vehicle that is equipped with a CVT, it is extremely important that the PCM and TCM both have the latest software calibrations. 8. Do not allow the battery charger to time out or the charging rate to climb above 13.5 volts during the flash process. 9. The StarSCAN(R) and StarMOBILE(R) diagnostic tools fully support Internet connectivity and must be configured for your dealership's network. For help on setting up your StarSCAN(R) / StarMOBILE(R) for the dealership's network, refer to the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation' under the download center. 10. The operating software in the StarSCAN(R) and StarMOBILE(R) must be programmed with the latest software release level. The software level is visible in the blue header at the top of the StarSCAN(R) and StarMOBILE(R) Desktop Client screens. For instructions on how to update your scan tool, refer to the StarSCAN(R) / StarMOBILE(R) Software Update guide available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation' under the download center. PARTS REQUIRED SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 399 lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 400 - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 401 Engine Control Module: Removal and Replacement Powertrain Control Module - Removal REMOVAL CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. The PCM (2) is attached to the right-front inner fender (1) located in the engine compartment. To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect and isolate the negative battery cable. 2. Remove both wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal. 3. Remove wiper cowl (two screws, four pins). 4. Remove wiper cowl support (three bolts). 5. Remove air intake tube (four nuts). 6. Carefully unplug the four 38-way connectors (3) from PCM. 7. Remove three PCM mounting bolts (4), and remove PCM from vehicle. Powertrain Control Module - Installation INSTALLATION CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 402 1. Position PCM (2) to vehicle. 2. Install three PCM mounting bolts (4). 3. Tighten bolts to 3-5 Nm (30-40 in. lbs.). 4. Check pin connectors in the PCM. Also check the four 38-way connectors (3) for corrosion or damage. Repair as necessary. 5. Install the four 38-way connectors (3) to PCM. 6. Install air intake tube (four nuts). 7. Install wiper cowl support (three bolts). 8. Install wiper cowl (two screws, four pins). 9. Install both wiper arms. 10. Connect negative battery cable. 11. Use the diagnostic scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Auto Shut Down Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 406 Main Relay (Computer/Fuel System): Diagrams Connector (IN PDC) RELAY-AUTO SHUT DOWN (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay Description DESCRIPTION The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description > Page 409 Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay - Operation PCM Output PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Removal REMOVAL The ASD relay is located in the engine compartment within the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal > Page 412 Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Installation INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Fuel Pump Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay (In PDC) Fuel Pump Relay: Diagrams Fuel Pump Relay (In PDC) Connector (IN PDC) RELAY-FUEL PUMP (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay (In PDC) > Page 419 Fuel Pump Relay: Diagrams Fuel Pump Speed Relay (HEV) (In PDC) Connector (HEV) - (IN PDC) RELAY-FUEL PUMP SPEED (HEV) - (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Description Fuel Pump Relay: Description and Operation Description DESCRIPTION The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the power distribution center cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Description > Page 422 Fuel Pump Relay: Description and Operation Operation OPERATION The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shut-down the ground circuit to the fuel pump relay in approximately 1-3 seconds unless the engine is operating or the starter motor is engaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Service and Repair > Removal Fuel Pump Relay: Service and Repair Removal REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on power distribution center cover for relay location. 1. Remove power distribution center cover. 2. Remove relay from power distribution center. 3. Check condition of relay terminals and power distribution center connector terminals for damage or corrosion. Repair or replace as necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the power distribution center connector). Repair or replace as necessary before installing relay. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Service and Repair > Removal > Page 425 Fuel Pump Relay: Service and Repair Installation INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on power distribution center cover for relay location. 1. Install relay to power distribution center. 2. Install cover to power distribution center. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Auto Shut Down Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 429 Main Relay (Computer/Fuel System): Diagrams Connector (IN PDC) RELAY-AUTO SHUT DOWN (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay Description DESCRIPTION The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description > Page 432 Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay - Operation PCM Output PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Removal REMOVAL The ASD relay is located in the engine compartment within the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal > Page 435 Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Installation INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 440 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 32 Way Air Bag Control Module: Diagrams Occupant Restraint Controller Module C1 (Body) 32 Way Connector C1 - (BODY) 32 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (BODY) 32 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 32 Way > Page 443 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 32 Way > Page 444 Air Bag Control Module: Diagrams Occupant Restraint Controller Module C2 (Side AIRBAG) 24 Way Connector C2 - (SIDE AIRBAG) 24 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (SIDE AIRBAG) 24 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description Air Bag Control Module: Description and Operation Occupant Restraint Controller - Description DESCRIPTION The Occupant Restraint Controller (ORC) (1) is secured with three screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel just behind the front seat crossmember and beneath the center floor console in the passenger compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow (3) printed on the label (2) on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges on three corners. The mounting flange to the right of the connector receptacle has an integral locating pin on its lower surface. Both right side flanges have round mounting holes, while the flange on the left side has a slotted mounting hole. A molded plastic electrical connector (4) with 2 receptacles, one containing 24 terminal pins and the other containing 32 terminal pins, exits the forward facing side of the ORC housing. These terminal pins connect the ORC to the vehicle electrical system through two dedicated take outs and connectors of the body wire harness. The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without the optional side curtain airbags. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description > Page 447 Air Bag Control Module: Description and Operation Occupant Restraint Controller - Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC) contains the Supplemental Restraint System (SRS) logic circuits and controls all of the SRS components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and for SRS diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. See: Restraint Systems/Air Bag Systems/Malfunction Lamp / Indicator/Description and Operation/Air Bag Indicator - Operation. The ORC microprocessor continuously monitors all of the SRS electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. The ORC receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Junction Block (JB), and a fused ignition switch output (run-start) circuit through a second fuse in the JB. The ORC receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw near the center of the instrument panel structural support. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the SRS components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup SRS protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from two remote front impact sensors located on the back of the right and left vertical members of the radiator support near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The ORC also monitors inputs from an internal rollover sensor and six additional remote impact sensors located on the left and right inner B-pillars and quarter inner panels to control deployment of the side curtain airbag units. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a SRS component deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. A second safing sensor within the ORC provides confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require SRS protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and either side curtain airbag unit. The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls or communication between other modules and devices that provide features of the SRS. The most reliable, efficient, and accurate means to diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal Air Bag Control Module: Service and Repair Occupant Restraint Controller - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side SRS components in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side SRS components will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the Supplemental Restraint System (SRS) components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. Remove the center console from the top of the floor panel transmission tunnel. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Removal. 3. Disconnect the two body wire harness connectors (1) from the Occupant Restraint Controller (ORC) (2) connector receptacles located on the forward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm on each connector. 4. Remove the three screws (3) that secure the ORC to the ORC bracket (4) that is welded onto the top of the floor panel transmission tunnel. 5. Remove the ORC from the floor panel transmission tunnel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal > Page 450 Air Bag Control Module: Service and Repair Occupant Restraint Controller - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side SRS components in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side SRS components will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the Supplemental Restraint System (SRS) components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. 1. Carefully position the Occupant Restraint Controller (ORC) (2) to the ORC bracket (4) on the floor panel transmission tunnel. When the ORC is correctly positioned, the arrow on the ORC label will be pointed forward in the vehicle and the locating pin on the bottom of the right ORC mounting flange will be engaged into the locating hole in the ORC bracket. 2. Install and tighten the three screws (3) that secure the ORC to the ORC bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 11 Nm (8 ft. lbs.). CAUTION: The lever arms of the wire harness connectors for the ORC MUST be in the unlatched position before they are inserted into their connector receptacles on the ORC or they may become damaged. 3. Reconnect the two body wire harness connectors (1) to the ORC connector receptacles located on the forward facing side of the module. Be certain that the latches on both connectors are each fully engaged. 4. Reinstall the center console onto the top of the floor panel transmission tunnel. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Installation. 5. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Starter Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 455 Starter Relay: Diagrams Connector (IN PDC) RELAY-STARTER MOTOR (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Starter Relay - Description Starter Relay: Description and Operation Starter Relay - Description DESCRIPTION The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See the power distribution center cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Starter Relay - Description > Page 458 Starter Relay: Description and Operation Starter Relay - Operation OPERATION The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Service and Repair > Starter Relay - Removal Starter Relay: Service and Repair Starter Relay - Removal REMOVAL The starter relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Disconnect and isolate negative battery cable. 2. Remove cover from Power Distribution Center (PDC) for relay identification and location. 3. Remove starter relay from PDC. 4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Service and Repair > Starter Relay - Removal > Page 461 Starter Relay: Service and Repair Starter Relay - Installation INSTALLATION 1. Push down firmly on starter relay until terminals are fully seated into PDC receptacle. 2. Install PDC cover. 3. Connect battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 468 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 469 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way Tire Pressure Monitor Receiver / Transponder: Diagrams Left Front Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT FRONT - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way > Page 472 Tire Pressure Monitor Receiver / Transponder: Diagrams Left Rear Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT REAR - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way > Page 473 Tire Pressure Monitor Receiver / Transponder: Diagrams Right Front Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-RIGHT FRONT - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Description DESCRIPTION PREMIUM SYSTEM A transponder, also known as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of the vehicle to provide the WCM/SKREEM with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description > Page 476 Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Operation OPERATION NUMBER: PREMIUM SYSTEM On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (Each WCM cycle ends when the vehicle has been shut off for a time period of approximately 15 minutes or longer). Once the WCM has performed this to the three locations that have transponders (left front, right front, and left rear wheel wells), it uses the process-of-elimination theory to know that the fourth sensor ID signal is coming from the left rear tire sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Removal Front FRONT TRANSPONDER 1. Raise and support the vehicle. 2. Remove the wheel well housing cover (2). 3. Remove the mounting nut (1) for the transponder (2). 4. Disconnect the electrical connector and remove the transponder (2) from the vehicle. Rear REAR TRANSPONDER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 479 1. Raise and support the vehicle. 2. Remove the mounting nut (1) for the transponder (2). 3. Disconnect the electrical connector (3) and remove the transponder (2) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 480 Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Installation Front FRONT TRANSPONDER 1. Install the transponder (2) to the vehicle and reconnect the electrical connector. 2. Install the mounting nuts (1) for the transponder (2) Tighten to 3 Nm (25 in. lbs.). 3. Install the wheel well housing cover (2). 4. Lower the vehicle. Rear REAR TRANSPONDER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 481 1. Install the transponder (2) to the vehicle and reconnect the electrical connector (3) and secure the harness to the stud (4). 2. Install the mounting nut (1) for the transponder (2). Tighten to 3 Nm (25 in. lbs.). 3. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description Control Module: Description and Operation Transmission Control Module - Description DESCRIPTION RFE - RLE TRANSMISSIONS The Transmission Control Module (TCM) is a sub-module within the Powertrain Control Module (PCM). The PCM is located on the right inner fender. EVT AHS-T TRANSMISSION TEHCM MOUNTING BOLTS On vehicles equipped with the AHS-T HEV transmission the TCM is imbedded into the Transmission Electronic Hydraulic Control Module (TECHM) that is mounted to the valve body and is not serviceable, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 488 Control Module: Description and Operation Transmission Control Module - Operation OPERATION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning/TCM Quick Learn BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 489 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: 42RLE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 490 545RFE EVT AHS-T SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 491 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures Control Module: Procedures STANDARD PROCEDURE - RESOLVER LEARN RESOLVER OFFSET LEARN TRIGGER EVT AHS-T TRANSMISSION The Resolver Offset Learn Trigger Procedure requires the use of a scan tool. This program allows the electronic variable transmission (EVT) AHS-T to re-calibrate itself. This will provide the proper transmission operation. The resolver offset learn procedure should be performed if any of the following procedures are performed: - Transmission Assembly Replacement - Transmission Electronic Hydraulic Control Module (TEHCM) Replacement - Flashing the TCM - Electric Motors Replacement - Valve Body Replacement or Recondition To perform the Resolver Offset Learn Trigger Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The shift lever position must stay in PARK until prompted to shift. - The calculated oil temperature must be above 15° C (60° F) and below 93° C (200° F) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 494 Control Module: Removal and Replacement Transmission Control Module - Removal REMOVAL WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. NOTE: If the TECHM is being flashed, removed or replaced, it is necessary to perform the Resolver Offset Learn Trigger procedure using the scan tool. 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove the drain plug, if equipped. 4. Remove the auxiliary oil pump mounting bolts (1). 5. Remove the auxiliary oil pump (2). 6. Remove the transmission oil pan (1), the primary oil filter (2) and the auxiliary oil filter (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 495 7. Lift up the passage sleeve locking tab (1). Remove the passage sleeve by gripping firmly on two ends and pulling the sleeve away. 8. Disconnect the TEHCM 2-way electrical jumper connector (1) from the internal transmission harness. 9. Disconnect the TEHCM electrical connector (1) from the valve body (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 496 10. Remove the TEHCM side mounting bolts (1) and main mounting bolts (2) from the valve body. 11. Disconnect the TEHCM jumper harness. 12. If necessary remove the TECHM filter screen (1). Transmission Control Module - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 497 INSTALLATION WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. NOTE: If the TECHM is being flashed, removed or replaced, it is necessary to perform the Resolver Offset Learn Trigger procedure using the scan tool. 1. Install the filter screen onto the TEHCM. TEHCM JUMPER CONNECTOR 2. Connect the TEHCM jumper harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 498 TEHCM MOUNTING BOLTS 3. Install the TECHM heat sink bolts (1). Tighten the bolts to 7 Nm (62 in.lbs.). 4. Install the TECHM mounting bolts (2). Tighten the bolts to 11 Nm (97 in.lbs.). 5. Connect the 2-way TEHCM electrical connector (1). 6. Connect the TEHCM electrical connector (1) to the valve body. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 499 NOTE: Orientate the alignment tab inside the passage sleeve with the slot in the electrical connector of the control solenoid valve assembly. Push the sleeve straight into the case bore and connector. Do NOT rotate the sleeve at any time. Ensure the sleeve is fully seated into the case. When the sleeve is properly installed, the distance from the case surface to the end of the sleeve should be 14-16 mm. 7. Lubricate the seals on the passage sleeve with DEXRON(R) VI. Install the passage sleeve (2). Push down on the passage locking tab (1) to secure. NOTE: Using a suitable solvent, clean the oil pan and magnet. 8. Install the auxiliary oil filter assembly (3). 9. Install the primary oil filter assembly (2). 10. Install the oil pan gasket and the oil pan (1) onto the transmission case. Install the oil pan bolts. Tighten the oil pan bolts to 27 Nm (19 ft.lbs.). 11. Install the auxiliary oil pump (2) with a NEW gasket. 12. Install the auxiliary oil pump bolts (1). Tighten the bolts to 11 Nm (97 in.lbs.). 13. Check and fill the transmission as necessary with DEXRON(R) VI transmission fluid. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 503 Transmission Control System Relay: Diagrams Connector (IN PDC) RELAY-TRANSMISSION CONTROL (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way Control Module: Diagrams Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way Connector C1 (HEV) - (HEADLAMP AND DASH) 16 WAY MODULE-FINAL DRIVE CONTROL (HEV) - (HEADLAMP AND DASH) 16 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way > Page 509 Control Module: Diagrams Final Drive Control Module C2 (HEV) (Headlamp And Dash) 4 Way Connector C2 (HEV) - (HEADLAMP AND DASH) 4 WAY MODULE-FINAL DRIVE CONTROL (HEV) - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description Control Module: Description and Operation Final Drive Control Module - Description DESCRIPTION FDCM (Final Drive Control Module) is an electronic module that controls the shifting of the AWD new "Active on Demand" MP3010 single speed transfer case. This plastic cased module is packaged in the (Pedal Assembly) MAG bracket for the HB/HG HEV vehicle. Communication is via the CAN serial bus. The FDCM is installed inside the passenger compartment behind the driver side knee bolster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 512 Control Module: Description and Operation Final Drive Control Module - Operation OPERATION POWER UP/DOWN The Final Drive Control Module (FDCM) will power up with an OFF/ON transition of the hard wired ignition switch input, or with the presence of active CAN C communications. The FDCM will power down when the vehicle ignition switch transitions from ON to OFF, or there are no CAN C messages, or there are no system requirements that dictate the controller to remain active START-UP DIAGNOSTICS When the FDCM is activated, the internal circuitry will undergo a diagnostic procedure. The controller will examine all inputs and outputs for short circuits to ground, short circuits to battery and open circuits and will also verify proper CPU and memory operation. If a fault is detected, a message will be sent out over the CAN C bus to the Cluster based Electronic Vehicle Information Center (EVIC) indicating that service is recommended. After passing all diagnostic tests, the controller will receive and process inputs and produce the appropriate outputs. Proper monitoring of the controller inputs and outputs performance will continue. INPUTS/OUTPUTS The following are inputs to the FDCM: - Lateral Accelerometer - Transfer Case Mode Sensor Signal - 3 Direct Battery Feeds - Ignition RUN Sense - Sensor Grounds - Module Grounds - CAN C Bus The following are outputs of the FDCM: - 5V Sensor Supply - Transfer Case Bi-directional Motor Control (A AND B) TRANSFER CASE MODE SENSOR SIGNAL The Transfer Case Mode Sensor Signal Input will provide the FDCM feedback about the position of the transfer case. The mode sensor will be a linear analog position sensor with a 1.4K +/- 20% potentiometer and a 1 K +/- 20% resistor that converts the motor shaft position into a multiplexed voltage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 513 SLIP CONTROL Slip Control increases torque to the front axle when a relative slip is detected between the front and the rear prop shafts. Slip Control adjusts according to the vehicle speed and allows a permissible slip. Utilizes a closed loop strategy for permissible slip and speed of engagement. STABILITY CONTROL Stability control modifies the torque request based upon the vehicle dynamics under the over-steer and under-steer conditions. It monitors the yaw rate and the lateral acceleration to modify the clutch capacity to bring the vehicle back to a more neutral attitude. Compensates for high load conditions by monitoring the vehicle acceleration and changing the torque capacity. REGENERATIVE BRAKING STRATEGY During the event of regenerative braking the software splits the torque indicated by the signal axle in a ratio of 47:53 front and rear respectively. This torque split is to be modified to achieve optimum efficiency levels during a braking event. MODES OF OPERATION Normal Operation This mode is achieved by the ignition being switched in the RUN position, which powers up the 5V regulator and generates the appropriate RESET for the microprocessor. This mode also includes any required power-up system checks. Shut Down Mode This mode is activated when the ignition switch turned to the off position. The FDCM will perform any required Shut Down tasks prior to turning off the 5V regulator. Limp-In Mode This mode is entered when the FDCM has detected an error condition that prevents the system from performing its' required task. The FDCM operation will vary depending from modified operation to total system shut down based on the failure that has occurred. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal Control Module: Service and Repair Final Drive Control Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect the module electrical connectors. 3. Using a trim stick C-4755 or equivalent, gently pry back on the retaining tabs on the mounting plate and remove module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal > Page 516 Control Module: Service and Repair Final Drive Control Module - Installation INSTALLATION 1. Place the final drive control module in its location on the mounting plate and firmly snap into place. 2. Connect the electrical connectors. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Window Defogger Relay is located in the Junction Block (JB). Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 521 Heated Glass Element Relay: Diagrams Connector (IN JB) RELAY-REAR WINDOW DEFOGGER (IN JB) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Description and Operation > Rear Defogger Relay - Description Heated Glass Element Relay: Description and Operation Rear Defogger Relay - Description DESCRIPTION The rear window defogger (EBL) relay (1) is an International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The EBL relay is a electromechanical device that switches battery current through a fuse in the power distribution center (PDC) to the rear window defogger grid and to the outside mirror heating grids. The EBL relay is energized when the relay coil is provided a ground path by the rear window defogger relay control in the front control module (FCM). The EBL relay is located in the junction block (JB) in the passenger compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Description and Operation > Rear Defogger Relay - Description > Page 524 Heated Glass Element Relay: Description and Operation Rear Defogger Relay - Operation OPERATION The ISO-standard rear window defogger (EBL) relay is an electromechanical switch that uses a low current input controlled by the front control module (FCM) to control the high current output to the rear window defogger grid lines. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the rear window defogger grid lines. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The EBL relay terminals are connected to the vehicle electrical system through a receptacle in the junction block (JB). The inputs and outputs of the EBL relay include: - The common feed terminal (30) receives fused battery current at all times. - The coil ground terminal (85) receives a ground through the EBL relay control circuit only when the front control module (FCM) electronically pulls the circuit to ground. - The coil battery terminal (86) receives fused battery current through an ignition switch output circuit only when the ignition switch is in RUN. - The normally open terminal (87) provides battery current to the rear window defogger grid lines through the EBL relay output circuit only when the EBL relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the EBL relay coil is de-energized. The EBL relay cannot be adjusted or repaired and must be replaced if inoperative or damaged. See Wiring Information for diagnosis and testing of the EBL relay and for complete rear window defogger (EBL) wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Service and Repair > Rear Defogger Relay - Removal Heated Glass Element Relay: Service and Repair Rear Defogger Relay - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the trim cover from the cowl (2) on the driver side of the vehicle. 3. Locate the junction block (JB) (1). NOTE: Refer to the fuse and relay map on the inside of the JB cover for EBL relay location. 4. Remove the EBL relay from the JB. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Service and Repair > Rear Defogger Relay - Removal > Page 527 Heated Glass Element Relay: Service and Repair Rear Defogger Relay - Installation INSTALLATION NOTE: Refer to the fuse and relay map on the inside of the junction block (JB) cover for EBL relay location. 1. Position the EBL relay to the JB (1). 2. Align the EBL relay terminals with the terminal cavities in the JB receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the trim cover onto the driver side cowl (2).See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Description and Operation/Junction Block - Description. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Rear Wiper, High/Low, and On/Off Relays are located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Relay-Wiper High/Low Wiper Relay: Diagrams Relay-Wiper High/Low Connector (IN PDC) RELAY-WIPER HIGH/LOW (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Relay-Wiper High/Low > Page 534 Wiper Relay: Diagrams Relay-Wiper On/Off Connector (IN IPM) RELAY-WIPER ON/OFF (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Relay-Wiper High/Low > Page 535 Wiper Relay: Diagrams Relay-Wiper-Rear Connector (IN IPM) RELAY-WIPER-REAR (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description Wiper Relay: Description and Operation High and Low Wiper Relay - Description DESCRIPTION The wiper high/low relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper high/low relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. The wiper high/low relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 538 Wiper Relay: Description and Operation High and Low Wiper Relay - Operation OPERATION The wiper high/low relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the front wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the output of the wiper on/off relay at all times through the wiper on/off relay output circuit. Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper high/low relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current when the ignition switch is in the On or Accessory positions from a fuse in the IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the high speed brush of the wiper motor through a wiper high/low relay high speed output circuit, and is connected to the high speed brush whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to the low speed brush of the wiper motor through a wiper high/low relay low speed output circuit, and is connected to the low speed brush whenever the relay is de-energized. The wiper high/low relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 539 Wiper Relay: Description and Operation ON and OFF Wiper Relay - Description DESCRIPTION The wiper on/off relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper on/off relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. The wiper on/off relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 540 Wiper Relay: Description and Operation ON and OFF Wiper Relay - Operation OPERATION The wiper on/off relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper on/off relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper on/off relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the common feed terminal of the wiper high/low relay at all times through the wiper on/off relay output circuit. Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper on/off relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit, and provides battery current to the wiper on/off relay output circuit whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times through a take out of the headlamp and dash wire harness with an eyelet terminal connector that is secured by a screw to the front end sheet metal, and is connected to the wiper on/off relay output circuit whenever the relay is de-energized. The wiper on/off relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 541 Wiper Relay: Description and Operation High and Low Wiper Relay - Description DESCRIPTION The wiper high/low relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper high/low relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. The wiper high/low relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. High and Low Wiper Relay - Operation OPERATION The wiper high/low relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the front wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the output of the wiper on/off relay at all times through the wiper on/off relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper high/low relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current when the ignition switch is in the On or Accessory positions from a fuse in the IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the high speed brush of the wiper motor through a wiper high/low relay high speed output circuit, and is connected to the high speed brush whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to the low speed brush of the wiper motor through a wiper high/low relay low speed output circuit, and is connected to the low speed brush whenever the relay is de-energized. The wiper high/low relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. ON and OFF Wiper Relay - Description DESCRIPTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 542 The wiper on/off relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper on/off relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. The wiper on/off relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. ON and OFF Wiper Relay - Operation OPERATION The wiper on/off relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper on/off relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper on/off relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the common feed terminal of the wiper high/low relay at all times through the wiper on/off relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper on/off relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit, and provides battery current to the wiper on/off relay output circuit whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times through a take out of the headlamp and dash wire harness with an eyelet terminal connector that is secured by a screw to the front end sheet metal, and is connected to the wiper on/off relay output circuit whenever the relay is de-energized. The wiper on/off relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Rear Wiper Relay - Description DESCRIPTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 543 The rear wiper relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The rear wiper relay is located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The rear wiper relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Rear Wiper Relay - Operation OPERATION The rear wiper relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the rear wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear wiper relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the rear wiper relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the rear wiper motor through the rear wiper motor control circuit. When the rear wiper relay is de-energized, the common feed terminal is connected to ground. When the rear wiper relay is energized, the common feed terminal of the relay is connected to battery current from a fuse in the Power Distribution Center (PDC) through a fused B(+) circuit. Coil Ground Terminal - The coil ground terminal (85) is connected to the relay control output of the FCM through the rear wiper relay control circuit. The FCM controls the ground path for this circuit internally to energize or de-energize the rear wiper relay based upon its programming, rear wiper and washer request messages received from the Electro mechanical Instrument Cluster (EMIC) over the Controller Area Network (CAN) data bus, and a hard wired input from the rear wiper motor park switch. - Coil Battery Terminal - The coil battery terminal (86) is connected to battery current from a fuse in the PDC through a fused B(+) circuit at all times. - Normally Open Terminal - The normally open terminal (87) is connected to battery current from a fuse in the PDC through a fused B(+) circuit at all times. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times. The rear wiper relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Hood Ajar Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Hood Ajar Switch > Page 550 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 551 Hood Sensor/Switch (For Alarm): Diagrams Connector (HEV) - 2 WAY SWITCH-HOOD AJAR 2 (HEV) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in three different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic market vehicles equipped with either an optional remote starter system or the optional Hybrid Electric Vehicle (HEV) system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole. For the vehicle theft and remote start applications, the switch is secured within the stamped metal inner left fender mounting flange within the engine compartment. For the HEV applications, the switch is secured within the stamped metal inner right fender mounting flange within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system or HEV system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description > Page 554 Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export market vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Front Control Module (FCM). The FCM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic market vehicles only - white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the FCM and the hood ajar switch sense input of the FCM. The FCM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. When the hood switch is closed (hood is open), the remote start feature is disabled. In the Hybrid Electric Vehicle (HEV) system application (white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between ground and the hood ajar switch sense input of the Powertrain Control Module (PCM). The PCM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. When the hood switch is closed (hood is open), the gasoline engine auto-start feature is disabled. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting hole, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the FCM or PCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export market vehicle theft, domestic market remote starter or the HEV systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Removal Striker STRIKER NOTE: Vehicles equipped with two hood ajar switches are also equipped with two strikers. NOTE: The hood ajar switch strikers are not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using hand pressure, slide the hood ajar switch striker (2) toward the large end of the keyed mounting hole (3) in the inner hood panel reinforcement (1) far enough to disengage it. 3. Remove the striker from the inner hood panel reinforcement and discard. Switch SWITCH NOTE: Some vehicles are equipped with two hood ajar switches. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 3. From the top of the left or right front fender inner shield, squeeze the two hood ajar switch latch tabs (1) together and pull the switch upward out of Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal > Page 557 the mounting hole (2). 4. Pull the hood ajar switch up through the hole far enough to access and disconnect the wire harness connector (3) from the switch connector receptacle. 5. Remove the hood ajar switch from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal > Page 558 Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Installation Striker STRIKER NOTE: Vehicles equipped with two hood ajar switches are also equipped with two strikers. NOTE: The hood ajar switch striker caps are not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) into the large end of the keyed mounting hole (3) in the inner hood panel reinforcement (1) over the hood ajar switch. 2. Using hand pressure, slide the striker upward into the small end of the mounting hole in the inner hood panel reinforcement until it is fully engaged. 3. Close and latch the hood. Switch SWITCH NOTE: Some vehicles are equipped with two hood ajar switches. 1. Position the hood ajar switch (1) near the mounting hole (2) in the left front fender inner shield. 2. Reconnect the wire harness connector (3) to the switch connector receptacle. 3. Insert the switch into the mounting hole until the integral switch latch tabs lock it into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal > Page 559 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. 5. Close and latch the hood. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Park Assist Sensor 8 (Park Assist) (Fascia RPA Harness) 3 Way Parking Assist Distance Sensor: Diagrams Park Assist Sensor 8 (Park Assist) (Fascia RPA Harness) 3 Way Connector (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY SENSOR-PARK ASSIST 8 (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Park Assist Sensor 8 (Park Assist) (Fascia RPA Harness) 3 Way > Page 565 Parking Assist Distance Sensor: Diagrams Park Assist Sensor 9 (Park Assist) (Fascia RPA Harness) 3 Way Connector (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY SENSOR-PARK ASSIST 9 (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Park Assist Sensor 8 (Park Assist) (Fascia RPA Harness) 3 Way > Page 566 Parking Assist Distance Sensor: Diagrams Park Assist Sensor 10 (Park Assist) (Fascia RPA Harness) 3 Way Connector (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY SENSOR-PARK ASSIST 10 (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Park Assist Sensor 8 (Park Assist) (Fascia RPA Harness) 3 Way > Page 567 Parking Assist Distance Sensor: Diagrams Park Assist Sensor 11 (Park Assist) (Fascia RPA Harness) 3 Way Connector (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY SENSOR-PARK ASSIST 11 (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Description and Operation > Park Assist Sensor - Description Parking Assist Distance Sensor: Description and Operation Park Assist Sensor - Description DESCRIPTION Vehicles equipped with the park assist system have four park assist sensors (1) installed on the rear bumper fascia. Only the membrane (3) of each sensor is visible through a hole in the outer vertical surface of the fascia. The remainder of each sensor including the sensor mounting bracket, the sensor spacer and the sensor wiring connection is concealed behind the fascia. A sensor wire harness behind the fascia connects the sensors to the vehicle electrical system. Each of the four sensors is identical in construction and is interchangeable. The electronic circuitry and a communication chip for each sensor is enclosed and protected within the molded black plastic sensor housing. The housing includes an integral connector receptacle (4) and two integral latch tabs (2). The sensor membrane extends from the surface of the sensor housing, and is finished to match or contrast with the outer surface of the fascia. The numbering system for the park assist sensors allows for up to twelve sensors on the vehicle, six front and six rear. The sensors are numbered in a clockwise manner starting at the left front bumper. The left front sensor (if equipped with front park assist) is the number 1 sensor. The numbering continues in a clockwise direction around the vehicle. Since this vehicle uses only four rear sensors, sensor numbers 7 and 12 are omitted, so the left rear sensor is the number 11 sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Description and Operation > Park Assist Sensor - Description > Page 570 A resilient O-ring spacer around the circumference of each of the four sensor membranes (2) isolates the membrane from the openings in the fascia (1). Each sensor is snapped into its own dedicated molded plastic mounting bracket. Each mounting bracket is heat-staked to the back side of the rear fascia. The park assist sensors cannot be adjusted or repaired. If ineffective or damaged they must be replaced. The sensors and the spacers are each available for individual service replacement. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Description and Operation > Park Assist Sensor - Description > Page 571 Parking Assist Distance Sensor: Description and Operation Park Assist Sensor - Operation OPERATION The park assist sensors are ultrasonic transceivers that are completely controlled by the park assist module. The sensors transmit and receive ultrasonic signals. The sensors each receive battery current and ground in parallel from the module, but are each connected to individual dedicated serial bus communication circuits to the module. Each sensor membrane is oscillated, then quieted by the module in a pulsing fashion. While the sensor membrane oscillates, it emits an ultrasonic signal. This signal will bounce or echo off of objects in the path of the vehicle. While quieted, each membrane receives the echoes of the ultrasonic signals it and the other sensors have transmitted. The sensors then communicate this echo data over the serial bus lines back to the module. The microprocessor in the module uses the intervals between the ultrasonic transmission and reception data from the sensors to calculate the distance to any obstacles identified by the ultrasonic echoes. The hard wired circuits between components related to the park assist sensors may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the park assist sensors or the electronic controls or communication between modules and other devices that provide some features of the park assist system. The most reliable, efficient, and accurate means to diagnose the park assist sensors or the electronic controls and communication related to park assist sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Park Assist Sensor - Removal Parking Assist Distance Sensor: Service and Repair Park Assist Sensor - Removal REMOVAL NOTE: The park assist sensors (3) and the sensor spacers (O-rings) are each available for separate service replacement. The sensor brackets (5) are bonded to and integral to the back side of the rear bumper fascia (2). 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. NOTE: The two outboard rear park assist sensors can be accessed for service with the rear bumper fascia installed on the vehicle. 2. For the two inboard rear park assist sensors only, remove the bumper fascia from the rear of the vehicle. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Removal. 3. From the back of the fascia (2), disconnect the wire harness connector (4) from the park assist sensor (3) connector receptacle. 4. Carefully pry the sensor bracket (5) latch features (1) away from the top and bottom latch tabs of the sensor far enough to disengage the sensor from the bracket. 5. Disengage the O-ring spacer from around the circumference of the sensor membrane protrusion. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Park Assist Sensor - Removal > Page 574 Parking Assist Distance Sensor: Service and Repair Park Assist Sensor - Installation INSTALLATION NOTE: The park assist sensors (3) and the sensor spacers (O-rings) are each available for separate service replacement. The sensor brackets (5) are bonded to and integral to the back side of the rear bumper fascia (2). 1. Engage the O-ring spacer around the circumference of the sensor membrane protrusion. NOTE: Production and all service replacement O-ring spacers are tapered. The wide side (base) of the O-ring should be seated against the sensor housing and the narrow side should be oriented toward the outer surface of the sensor membrane and the rear fascia. 2. Align and insert the sensor (3) into the sensor bracket (5) on the back of the rear bumper fascia (2) until the bracket latch features (1) are fully engaged over the top and bottom latch tabs of the sensor. Be certain that the sensor membrane is flush with the outer surface of the fascia. NOTE: Be certain that each sensor membrane is properly centered in the openings of the rear fascia and that the O-ring spacers are not pinched. Improper centering or pinched O-rings can be detrimental to proper park assist sensor operation. 3. From the back of the fascia, reconnect the wire harness connector (4) to the sensor connector receptacle. 4. For the two inboard rear park assist sensors only, reinstall the bumper fascia onto the rear of the vehicle. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Installation. 5. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Locations > Page 578 Pedal Positioning Sensor: Diagrams Connector - (INSTRUMENT PANEL) 3 WAY SENSOR-ADJUSTABLE PEDALS - (INSTRUMENT PANEL) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 582 Pedal Positioning Switch: Diagrams Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-ADJUSTABLE PEDALS - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Service and Repair > Removal Pedal Positioning Switch: Service and Repair Removal REMOVAL 1. Remove the lower drivers side bezel. 2. Disconnect the electrical connector (2) from the adjustable pedal switch (1). 3. Remove the switch from the lower drivers side bezel by squeezing the retaining clips together and pushing the switch outwards Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Service and Repair > Removal > Page 585 Pedal Positioning Switch: Service and Repair Installation INSTALLATION 1. Install the switch (1) to the lower drivers side bezel by pushing the switch inwards seating the retaining clips to the lower drivers side bezel. 2. Reconnect the electrical connector (2) to the adjustable pedal switch (1). 3. Install the lower drivers side bezel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch > Page 590 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way Remote Switch: Diagrams Left Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-LEFT - (STEERING WHEEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way > Page 593 Remote Switch: Diagrams Right Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-RIGHT - (STEERING WHEEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Remote Radio Switches Description Remote Switch: Description and Operation Remote Radio Switches - Description DESCRIPTION Two rocker-type switches are mounted in the sides of the rear (instrument panel side) steering wheel trim cover. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player or CD player. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Remote Radio Switches Description > Page 596 Remote Switch: Description and Operation Remote Radio Switches - Operation OPERATION The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Instrument cluster through the clockspring. The instrument cluster sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the instrument cluster senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Controller Area Network (CAN) data bus to the radio. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 597 Remote Switch: Testing and Inspection REMOTE RADIO SWITCHES Any diagnosis of the audio system should begin with the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Remove the remote radio switch(es) (1) and (2) from the steering wheel See: Service and Repair/Remote Radio Switches - Removal. 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test table. If the remote radio switch resistances are not as indicated, replace the inoperative switch. REMOTE RADIO SWITCH TEST Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal Remote Switch: Service and Repair Remote Radio Switches - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag (5) from the steering wheel (1). See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag - Removal. 3. Remove the speed control switch (3) or (6) located on the same side of the steering wheel as the remote radio switch that is being serviced. See: Sensors and Switches - Cruise Control/Cruise Control Switch/Service and Repair/Speed Control Switch - Removal. 4. Disconnect the steering wheel wire harness connector from the connector receptacle of the remote radio switch. 5. Disengage the four remote radio switch latches that secure the switch to the inside of the mounting hole in the steering wheel rear trim cover. 6. From the outside of the steering wheel rear trim cover, remove the remote radio switch (2) from the trim cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal > Page 600 Remote Switch: Service and Repair Remote Radio Switches - Installation INSTALLATION 1. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch latches is fully engaged in the mounting hole of the steering wheel rear trim cover. 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch. 4. Install the speed control switch onto the steering wheel. See: Sensors and Switches - Cruise Control/Cruise Control Switch/Service and Repair/Speed Control Switch - Installation. 5. Install the driver side airbag to the steering wheel. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag - Installation. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations > Page 604 Vacuum Brake Booster Diaphragm Position Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 3 WAY SENSOR-BOOSTER TRAVEL (HEV) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Description DESCRIPTION The travel sensor (7) is mounted on power brake booster (1) below and to the left of the master cylinder, and has one electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description > Page 607 Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Operation OPERATION The travel sensor is a three-wire potentiometer that varies the voltage output as the position of the booster diaphragm changes. The RBS module uses the position information to determine the amount of booster movement and hydraulic brake application. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor Removal Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor - Removal REMOVAL 1. Disconnect the electrical connector (2) from the travel sensor (1). NOTE: The retainer clip does not need to be removed, only pushed up slightly to disengage the tabs on the sensor. 2. Using a small screw driver (4) or another suitable tool, push up on the retainer clip (2) and pull the travel sensor (3) from the power brake booster (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor Removal > Page 610 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor Installation INSTALLATION NOTE: When replacing the travel sensor, the Anti-Lock Brake Module (ABM) must be initialized using the scan tool. To initialize the ABM perform the ABS VERIFICATION TEST - HEV. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test . NOTE: Verify that the surface is clean, the old O-ring is removed, and the new O-ring is properly positioned on the sensor. 1. With a slight twisting motion, push the travel sensor (3) into the power brake booster (1). There should be a slight snapping sound as the retainer clip (3) seats into position. 2. Verify that the travel sensor retainer clip (3) snapped into place. 3. Connect the electrical connector (2) to the travel sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Hood Ajar Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Hood Ajar Switch > Page 617 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 618 Hood Sensor/Switch (For Alarm): Diagrams Connector (HEV) - 2 WAY SWITCH-HOOD AJAR 2 (HEV) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in three different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic market vehicles equipped with either an optional remote starter system or the optional Hybrid Electric Vehicle (HEV) system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole. For the vehicle theft and remote start applications, the switch is secured within the stamped metal inner left fender mounting flange within the engine compartment. For the HEV applications, the switch is secured within the stamped metal inner right fender mounting flange within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system or HEV system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description > Page 621 Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export market vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Front Control Module (FCM). The FCM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic market vehicles only - white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the FCM and the hood ajar switch sense input of the FCM. The FCM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. When the hood switch is closed (hood is open), the remote start feature is disabled. In the Hybrid Electric Vehicle (HEV) system application (white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between ground and the hood ajar switch sense input of the Powertrain Control Module (PCM). The PCM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. When the hood switch is closed (hood is open), the gasoline engine auto-start feature is disabled. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting hole, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the FCM or PCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export market vehicle theft, domestic market remote starter or the HEV systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Removal Striker STRIKER NOTE: Vehicles equipped with two hood ajar switches are also equipped with two strikers. NOTE: The hood ajar switch strikers are not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using hand pressure, slide the hood ajar switch striker (2) toward the large end of the keyed mounting hole (3) in the inner hood panel reinforcement (1) far enough to disengage it. 3. Remove the striker from the inner hood panel reinforcement and discard. Switch SWITCH NOTE: Some vehicles are equipped with two hood ajar switches. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 3. From the top of the left or right front fender inner shield, squeeze the two hood ajar switch latch tabs (1) together and pull the switch upward out of Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal > Page 624 the mounting hole (2). 4. Pull the hood ajar switch up through the hole far enough to access and disconnect the wire harness connector (3) from the switch connector receptacle. 5. Remove the hood ajar switch from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal > Page 625 Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Installation Striker STRIKER NOTE: Vehicles equipped with two hood ajar switches are also equipped with two strikers. NOTE: The hood ajar switch striker caps are not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) into the large end of the keyed mounting hole (3) in the inner hood panel reinforcement (1) over the hood ajar switch. 2. Using hand pressure, slide the striker upward into the small end of the mounting hole in the inner hood panel reinforcement until it is fully engaged. 3. Close and latch the hood. Switch SWITCH NOTE: Some vehicles are equipped with two hood ajar switches. 1. Position the hood ajar switch (1) near the mounting hole (2) in the left front fender inner shield. 2. Reconnect the wire harness connector (3) to the switch connector receptacle. 3. Insert the switch into the mounting hole until the integral switch latch tabs lock it into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal > Page 626 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. 5. Close and latch the hood. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Locations > Page 630 Pedal Positioning Sensor: Diagrams Connector - (INSTRUMENT PANEL) 3 WAY SENSOR-ADJUSTABLE PEDALS - (INSTRUMENT PANEL) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 634 Pedal Positioning Switch: Diagrams Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-ADJUSTABLE PEDALS - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Service and Repair > Removal Pedal Positioning Switch: Service and Repair Removal REMOVAL 1. Remove the lower drivers side bezel. 2. Disconnect the electrical connector (2) from the adjustable pedal switch (1). 3. Remove the switch from the lower drivers side bezel by squeezing the retaining clips together and pushing the switch outwards Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Service and Repair > Removal > Page 637 Pedal Positioning Switch: Service and Repair Installation INSTALLATION 1. Install the switch (1) to the lower drivers side bezel by pushing the switch inwards seating the retaining clips to the lower drivers side bezel. 2. Reconnect the electrical connector (2) to the adjustable pedal switch (1). 3. Install the lower drivers side bezel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Driver Window/Door Lock Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Driver Window/Door Lock Switch > Page 642 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Left Front Door) 8 Way Power Door Lock Switch: Diagrams Driver Window/Door Lock Switch C1 (Left Front Door) 8 Way Connector C1 - (LEFT FRONT DOOR) 8 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (LEFT FRONT DOOR) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Left Front Door) 8 Way > Page 645 Power Door Lock Switch: Diagrams Driver Window/Door Lock Switch C2 (Left Front Door) 6 Way Connector C2 - (LEFT FRONT DOOR) 6 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (LEFT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Left Front Door) 8 Way > Page 646 Power Door Lock Switch: Diagrams Passenger Window/Door Lock Switch (Right Front Door) 6 Way Connector - (RIGHT FRONT DOOR) 6 WAY SWITCH-WINDOW/DOOR LOCK-PASSENGER - (RIGHT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Power Lock Switch - Description Power Door Lock Switch: Description and Operation Power Lock Switch - Description DESCRIPTION A window/lock switch located in each front door trim panel. The driver's side window/lock switch includes the following: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, the window/lock switch houses individual master switches for each passenger door power window. The passenger side window/lock switch includes the following: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Window Switch - A two-way, momentary power window switch for the passenger side front door. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Power Lock Switch - Description > Page 649 Power Door Lock Switch: Description and Operation Power Lock Switch - Operation OPERATION The driver side window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single assembly. The switches in the window/lock switch can be diagnosed using conventional diagnostic tools and methods. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster (without memory). If equipped with the memory system, the circuitry is connected to the memory mirror module. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster or memory mirror input, which allows the instrument cluster or memory module to sense the switch position. Based upon the power lock switch input, the instrument cluster or memory module controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch in the window/lock switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch in the window/lock switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the switches in the window/lock switch. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Page 650 Power Door Lock Switch: Testing and Inspection WINDOW/DOOR LOCK SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the window/lock switch power window and power lock switches receive battery current through the circuit breaker in the Integrated Power Module (IPM). If only one LED in the door module is inoperative, replace the faulty door module. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty window/lock switch. Refer to the appropriate wiring information. 1. Disconnect and isolate the negative battery cable. Remove the window/lock switch from the door trim panel. Disconnect the door wire electrical connectors from the switch. 2. Test the switch continuity. See the Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty window/lock switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal Power Door Lock Switch: Service and Repair Power Lock Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, start at the rear of the switch and pry up to remove from door trim panel. 3. Disconnect electrical harness connectors from switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal > Page 653 Power Door Lock Switch: Service and Repair Power Lock Switch - Installation INSTALLATION 1. Connect electrical harness connectors to switch. 2. Insert front end of switch into door trim panel opening. Press into place. 3. Connect battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 657 Power Mirror Switch: Diagrams Connector - (LEFT FRONT DOOR) 10 WAY SWITCH-MIRROR - (LEFT FRONT DOOR) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Power Mirror Switch - Description Power Mirror Switch: Description and Operation Power Mirror Switch - Description DESCRIPTION A power mirror switch is located on the driver's door trim panel, attached to the window/lock switch. The power mirror switch includes the following: - Power Mirror Selector Switch - A three-position rotary joystick switch selects the right or left power mirror for adjustment, or turns the power mirror system Off in the center position. - Power Mirror Adjustment Switch - A momentary joystick directional switch allows the driver to adjust the selected power mirror in the Up, Down, Right or Left directions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Power Mirror Switch - Description > Page 660 Power Mirror Switch: Description and Operation Power Mirror Switch - Operation OPERATION The power mirror switch circuitry is connected to battery current through a fuse in the IPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rotary joystick selector switch has three positions, one to select the right mirror, one to select the left mirror, and a center Off position. After the right or left mirror is selected, the joystick is moved to move the selected mirror Up, Down, Right or Left. In vehicles without Memory Mirrors the power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. In vehicles with Memory Mirrors the mirror switch connects to the driver power mirror module. The driver memory mirror module uses the mirror switch inputs to control the battery current and ground feeds to driver mirror motor and sends a CAN Bus message to the passenger mirror module. The passenger mirror module controls the battery current and ground feeds to passenger mirror motors based on the CAN bus message from the driver memory module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 661 Power Mirror Switch: Testing and Inspection POWER MIRROR SWITCH 1. Disconnect and isolate the battery negative cable. Remove the power mirror switch. Disconnect the wire harness connector from the switch. 2. Test the switch continuity. See the Switch Tests chart to determine if the continuity is correct for the suspect switch in each switch position. If not OK, replace the inoperative switch as required. POWER MIRROR SWITCH TEST Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal Power Mirror Switch: Service and Repair Power Mirror Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the window/lock switch See: Power Door Lock Switch/Service and Repair/Power Lock Switch - Removal. 3. Remove the power mirror switch from the window/lock switch assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal > Page 664 Power Mirror Switch: Service and Repair Power Mirror Switch - Installation INSTALLATION 1. Install power mirror switch to window/lock switch assembly. 2. Connect wire harness connectors to switches. 3. Install window/lock switch assembly See: Power Door Lock Switch/Service and Repair/Power Lock Switch - Installation. 4. Connect battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Driver Seat Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Driver Seat Switch > Page 669 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver Seat Switch (Left Seat) 11 Way Power Seat Switch: Diagrams Driver Seat Switch (Left Seat) 11 Way Connector - (LEFT SEAT) 11 WAY SWITCH-SEAT-DRIVER - (LEFT SEAT) 11 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver Seat Switch (Left Seat) 11 Way > Page 672 Power Seat Switch: Diagrams Passenger Seat Switch (Right Seat) 11 Way Connector - (RIGHT SEAT) 11 WAY SWITCH-SEAT-PASSENGER - (RIGHT SEAT) 11 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Power Seat Switch - Description Power Seat Switch: Description and Operation Power Seat Switch - Description DESCRIPTION The driver power seat can be adjusted in eight different ways using the power seat switch. The passenger power seat can be adjusted in four different ways. The power seat switch is located on the lower outboard side of the seat cushion on the seat cushion side shield on all models. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Power Seat Switch - Description > Page 675 Power Seat Switch: Description and Operation Power Seat Switch - Operation OPERATION When a power seat switch is actuated, a battery feed and a ground path are applied through the switch contacts to the power seat adjuster or recliner adjuster motor. The selected adjuster motor operates to move the seat or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. On vehicles equipped with memory system, a resistance signal is sent to the Memory Seat Module (MSM) via the Controller Area Network (CAN) bus circuit, when the driver memory seat switch control knob is actuated. The MSM is responsible for the 12v battery feed and ground path to the power seat adjuster motor. The adjuster motor operates to move the power seat adjuster mechanism through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker may result in motor damage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 676 Power Seat Switch: Testing and Inspection POWER SEAT SWITCH DRIVER SEAT WITHOUT MEMORY 1. Disconnect and isolate the negative battery cable. 2. Remove the power seat switch from the power seat. See: Service and Repair/Power Seat Switch - Removal. 3. Use an ohmmeter to test the continuity of the power seat switch. Refer to DRIVER SEAT SWITCH WITHOUT MEMORY TEST table. If not OK, replace the inoperative power seat switch. If switch test OK, See: Body and Frame/Seats/Testing and Inspection/Component Tests and General Diagnostics. PASSENGER SEAT 1. Disconnect and isolate the negative battery cable. 2. Remove the power seat switch from the power seat. See: Service and Repair/Power Seat Switch - Removal. 3. Use an ohmmeter to test the continuity of the power seat switch. Refer to PASSENGER SEAT SWITCH TEST table. If not OK, replace the inoperative power seat switch. If switch test OK, See: Body and Frame/Seats/Testing and Inspection/Component Tests and General Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 677 DRIVER SEAT WITH MEMORY 1. Disconnect and isolate the negative battery cable. 2. Remove the power seat switch from the power seat. See: Service and Repair/Power Seat Switch - Removal. 3. Use an ohmmeter to test the continuity of the power seat switch. Refer to DRIVER SEAT SWITCH WITH MEMORY table. If not OK, replace the inoperative power seat switch. If switch test OK, See: Body and Frame/Seats/Testing and Inspection/Component Tests and General Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch - Removal Power Seat Switch: Service and Repair Power Seat Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side panel from the seat and disconnect the electrical harness connector. 3. Using a small flat bladed tool, gently release the four mounting tabs that secure the power seat switch and separate switch from trim panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch - Removal > Page 680 Power Seat Switch: Service and Repair Power Seat Switch - Installation INSTALLATION 1. Position the power seat switch on the seat cushion side panel. Gently apply pressure to the switch until the four mounting tabs that secure the switch snap into place. 2. Connect the power seat switch electrical connector. 3. Install the seat cushion side panel on the seat. 4. Connect the battery negative cable. 5. Verify normal operation of the power seat assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations > Left Liftgate Pinch Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations > Left Liftgate Pinch Sensor > Page 685 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Diagrams > Left Liftgate Pinch Sensor (Power Liftgate) (Liftgate) 2 Way Power Trunk / Liftgate Hazard Sensor: Diagrams Left Liftgate Pinch Sensor (Power Liftgate) (Liftgate) 2 Way Connector (POWER LIFTGATE) - (LIFTGATE) 2 WAY SENSOR-LIFTGATE PINCH-LEFT (POWER LIFTGATE) - (LIFTGATE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Diagrams > Left Liftgate Pinch Sensor (Power Liftgate) (Liftgate) 2 Way > Page 688 Power Trunk / Liftgate Hazard Sensor: Diagrams Right Liftgate Pinch/Temperature Sensor (Power Liftgate) (Liftgate) 2 Way Connector (POWER LIFTGATE) - (LIFTGATE) 2 WAY SENSOR-LIFTGATE PINCH/TEMP-RIGHT (POWER LIFTGATE) - (LIFTGATE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Description and Operation > Pinch Sensor - Description Power Trunk / Liftgate Hazard Sensor: Description and Operation Pinch Sensor - Description DESCRIPTION Pinch sensors (2) are located on each side of the liftgate (1). These sensors look like weather-strips, however they consist of pieces of electrically conductive rubber (tapeswitch), wires, resistor, double sided tape, and a plastic carrier. They are used to indicate an obstruction during a power liftgate close cycle. The right side pinch sensor contains a thermistor that is integral to the pinch sensor assembly. The thermistor is a temperature sensor used by the power liftgate control module to enable proper liftgate operation in extreme climate conditions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Description and Operation > Pinch Sensor - Description > Page 691 Power Trunk / Liftgate Hazard Sensor: Description and Operation Pinch Sensor - Operation OPERATION During a power liftgate "close" cycle, if either of the two conductive rubber strips (tapeswitch) of the pinch sensor come in contact with an obstacle, the pinch sensor circuit is completed. This tells the power liftgate control module that a obstruction is felt. The control module will stop the liftgate immediately and return it to the full open position. The thermistor portion of the right pinch sensor provides the temperature signal to the power liftgate control module (temperature is provided when the pinch sensor is in an unpinched condition; when pinched, temperature is unavailable because the thermistor is shorted). As the outside temperature increases, the resistance reading decreases. As temperature decreases, the resistance reading increases. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Description and Operation > Page 692 Power Trunk / Liftgate Hazard Sensor: Testing and Inspection RIGHT PINCH SENSOR/THERMISTOR The thermistor portion of the right pinch sensor provides the temperature signal to the power liftgate control module (temperature is provided when the pinch sensor is in an unpinched condition; when pinched, temperature is unavailable because the thermistor is shorted). Refer to the RIGHT PINCH SENSOR/THERMISTOR DIAGNOSTIC TABLE to test the thermistor resistance. RIGHT PINCH SENSOR/THERMISTOR DIAGNOSTIC TABLE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Service and Repair > Pinch Sensor - Removal Power Trunk / Liftgate Hazard Sensor: Service and Repair Pinch Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove trim panel from liftgate, See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal. 3. Disconnect the pinch sensor wire harness connector (4). 4. Remove the clips/assembly holding the pinch sensor (2) to liftgate (1). 5. Feed the pinch sensor wire harness (5) out of the liftgate (1) and remove the sensor (2) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Service and Repair > Pinch Sensor - Removal > Page 695 Power Trunk / Liftgate Hazard Sensor: Service and Repair Pinch Sensor - Installation INSTALLATION WARNING: Use extreme caution when testing pinch sensor operation. 1. Route the pinch sensor wire harness (5) through the hole in the liftgate (1). Push the wire harness grommet into place until fully seated. 2. Position the pinch sensor (2) to the liftgate (1) and align the holes to the fastening clips. 3. Install the four clips holding the sensor to the liftgate. 4. Connect the pinch sensor wire harness connector (4). 5. Install the trim panel on the liftgate, See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Installation. 6. Connect the battery negative cable. 7. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes related to the pinch sensor. 8. Verify power liftgate system and pinch sensor operation. Cycle the power liftgate through one complete open and close cycle, during the final close cycle press the pinch sensor to verify the power liftgate detects an obstruction and returns to the full open position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Driver Heated Seat Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Driver Heated Seat Switch > Page 700 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Heated Seat Switch (Instrument Panel) 6 Way Seat Heater Switch: Diagrams Driver Heated Seat Switch (Instrument Panel) 6 Way Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-HEATED SEAT-DRIVER - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Heated Seat Switch (Instrument Panel) 6 Way > Page 703 Seat Heater Switch: Diagrams Left Rear Heated Seat Switch (Rear Seat) 6 Way Connector - (REAR SEAT) 6 WAY SWITCH-HEATED SEAT-LEFT REAR - (REAR SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Heated Seat Switch (Instrument Panel) 6 Way > Page 704 Seat Heater Switch: Diagrams Passenger Heated Seat Switch (Instrument Panel) 6 Way Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-HEATED SEAT-PASSENGER - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Heated Seat Switch (Instrument Panel) 6 Way > Page 705 Seat Heater Switch: Diagrams Right Rear Heated Seat Switch (Rear Seat) 6 Way Connector - (REAR SEAT) 6 WAY SWITCH-HEATED SEAT-RIGHT REAR - (REAR SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description Seat Heater Switch: Description and Operation Heated Seat Switch - Description Front DESCRIPTION The heated seat switches are both mounted in the instrument panel. The two switches are snapped into mounting holes in the instrument panel center bezel (1). The two heated seat switches (2) and (3) are identical in appearance and construction, except for the location of a keyway in the connector receptacle on the back of each switch. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles so that the two heated seat switches can only be connected to the proper heated seat. Each momentary, bidirectional rocker-type heated seat switch provides a resistor-multiplexed signal to the Cab Compartment Node (CCN). Each switch has a center neutral position and momentary Low and High positions so that the driver and the front seat passenger can select a preferred seat heating level. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Each switch also has one indicator lamp for back lighting of the switch when the ignition switch is in the Run position. The five LED indicator lamps in each heated seat switch cannot be repaired. If the LED lamps are faulty or damaged, or the switch is faulty or damaged the individual heated seat switch assembly must be replaced. Second Row DESCRIPTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description > Page 708 Momentary contact push button switch/modules (2) mounted in the front face of the second row center floor console (3) operate the heated second row seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated second row seat system. If any of the heated second row seat elements are inoperative or damaged one or more of the LED lamps in the switch/module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are inoperative or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. See: Service and Repair/Heated Seat Switch Removal for the switch/module replacement procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description > Page 709 Seat Heater Switch: Description and Operation Heated Seat Switch - Operation Front OPERATION The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistor multiplexed signal to the Cabin Compartment Node (CCN). The CCN is responsible for supplying the CAN bus message to the heated seat module, signaling the module to power the heated seat element of the selected seat and maintain the temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the CCN will go through the process again to change the temperature setting. If a heated seat switch is depressed a second time to the same position as the currently selected state, the CCN and heated seat module interprets the second input as a request to turn the seat heater OFF. The CCN will then signal the heated seat module to turn the heated seat elements for that seat off. The backlighting LED's in each of the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The ground side of the indicator lamp is divided by a separate lamp driver circuit in the CCN. Second Row OPERATION A Heated Seat Switch/Module is used to control the heated second row seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after thirty minutes of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue for another thirty minutes and the system will then be automatically turned off. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 710 Seat Heater Switch: Testing and Inspection HEATED SEAT SWITCH Refer to the Wiring section for complete heated seat system wiring diagrams. WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the heated seat elements do heat, disconnect the inoperative switch and check for continuity between the ground pin at the heated seat switch connector and ground. If there is no continuity, repair an open wire between ground and the heated seat switch connector. If there is continuity, replace the inoperative heated seat switch. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned Off, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Also refer to the Body Diagnostic Information for additional diagnosis and testing procedures. 2. Check the fused ignition switch output (run) fuse in the Power Distribution Center (PDC). If OK, go to 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run) fuse in the PDC. If OK, go to 4. If not OK, repair the open fused ignition switch output (run) circuit to the ignition switch as required. 4. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector from the connector receptacle on the back of the heated seat switch to be tested. Reconnect the battery negative cable. Turn the ignition switch to the Run position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the heated seat switch. If OK, go to 5. If not OK, repair the open fused ignition switch output (run) circuit to the PDC fuse as required. 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart below. If OK, See: Body and Frame/Relays and Modules - Body and Frame/Seat Heater Control Module/Testing and Inspection. Also refer to the Body Diagnostic Information for additional diagnosis and testing procedures. If not OK, replace the faulty heated seat switch. HEATED SEAT SWITCH CONTINUITY CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal Seat Heater Switch: Service and Repair Heated Seat Switch - Removal Front REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the center bezel (1) from the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the heated seat switch bezel and both switches from the center bezel as a unit. 4. From the back of the heated seat switch bezel (2), gently pry the switch free and push the heated seat switch out through the rear of the bezel. Second Row REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 713 1. Disconnect and isolate the battery negative cable. 2. Using an appropriate flat bladed tool, remove the heated seat switch/modules (2) from the rear center floor console (3) by gently prying up from the edge of the switch/module bezel (1). Take care not to scratch or damage the console or bezel in any way. 3. Disconnect the switch/module electrical connectors (2) and (4). 4. Using an appropriate flat bladed tool, remove the heated seat switch/module (3) from the bezel (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 714 Seat Heater Switch: Service and Repair Heated Seat Switch - Installation Front INSTALLATION NOTE: When installing the heated seat switches, be certain they are installed in the proper mounting holes of the heated seat switch bezel (2). The heated seat switches are identified by a keyway in the connector receptacle on the back of each switch. 1. From the back of the heated seat switch bezel, gently push the heated seat switch in through the rear of the bezel. 2. Install the center bezel on the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Cluster Bezel - Installation. 3. Connect the battery negative cable. 4. Verify heated seat system operation. Second Row INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 715 1. Align the tabs (1) of the switch/module (2) to the bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors (2) and (4). 3. Gently push the heated seat switch/module bezel (1) into the mounting hole in the center console (3) until it is securely in place. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 719 Seat Memory Switch: Diagrams Connector - (LEFT FRONT DOOR) 6 WAY SWITCH-MEMORY SELECTOR - (LEFT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Sunroof Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Sunroof Switch > Page 724 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Sunroof Switch (Headliner) 4 Way Sunroof / Moonroof Switch: Diagrams Sunroof Switch (Headliner) 4 Way Connector - (HEADLINER) 4 WAY SWITCH-SUNROOF - (HEADLINER) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Sunroof Switch (Headliner) 4 Way > Page 727 Sunroof / Moonroof Switch: Diagrams Sunroof/Power Liftgate Switch (Headliner) 6 Way Connector - (HEADLINER) 6 WAY SWITCH-SUNROOF/LIFTGATE PLG - (HEADLINER) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Power Top Switch - Removal Sunroof / Moonroof Switch: Service and Repair Power Top Switch - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Separate the overhead console from the headliner, by carefully pulling down on the front portion, toward the windshield, to release the retaining clips. 3. Release the sunroof switch retaining tab (2), disconnect the electrical connector (1) and remove the switch from the console. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Power Top Switch - Removal > Page 730 Sunroof / Moonroof Switch: Service and Repair Power Top Switch - Installation INSTALLATION 1. Position the switch (2) against the overhead console (1) and push the switch to seat properly in retaining clip (3). 2. Install the overhead console and seat the retaining clips (4) fully. 3. Connect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations > Page 734 Trunk / Liftgate Ajar Switch: Diagrams Connector - (LIFTGATE) 2 WAY SWITCH-LIFTGATE AJAR - (LIFTGATE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Description and Operation > Liftgate Ajar Switch - Description Trunk / Liftgate Ajar Switch: Description and Operation Liftgate Ajar Switch - Description LIFTGATE A liftgate ajar switch is standard equipment on this vehicle. The switch is concealed within and integral to the liftgate latch unit. The switch is a momentary leaf contact-type unit that is actuated by the liftgate latch mechanisms. An integral connector receptacle on the liftgate latch connects the liftgate ajar switch to the vehicle electrical system through the liftgate wire harness. The liftgate ajar switch cannot be adjusted or repaired and, if ineffective or damaged, the liftgate latch unit must be replaced. See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/Removal and Replacement/Latch - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Description and Operation > Liftgate Ajar Switch - Description > Page 737 Trunk / Liftgate Ajar Switch: Description and Operation Liftgate Ajar Switch - Operation LIFTGATE The liftgate ajar switch is actuated by the liftgate latch mechanism. When the liftgate is closed and properly latched, its liftgate ajar switch is an open circuit. When the liftgate is open or only partially latched, the liftgate ajar switch is a closed circuit. The liftgate ajar switch is hard wired in series between a body ground and the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC reads the hard wired liftgate ajar switch input through an internal pull-up, then uses this input to control many electronic functions and features of the vehicle. The liftgate ajar switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Power Liftgate Release Switch (Except Sunroof) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Power Liftgate Release Switch (Except Sunroof) > Page 742 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Power Liftgate Release Switch (Headliner) 4 Way Trunk / Liftgate Switch: Diagrams Power Liftgate Release Switch (Headliner) 4 Way Connector - (HEADLINER) 4 WAY SWITCH-LIFTGATE RELEASE PLG - (HEADLINER) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Power Liftgate Release Switch (Headliner) 4 Way > Page 745 Trunk / Liftgate Switch: Diagrams Sunroof/Power Liftgate Switch (Headliner) 6 Way Connector - (HEADLINER) 6 WAY SWITCH-SUNROOF/LIFTGATE PLG - (HEADLINER) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch - Installation Trunk / Liftgate Switch: Description and Operation Exterior Handle Switch - Installation DESCRIPTION All vehicles are equipped with a power liftgate exterior handle switch. The switch is integral to the power liftgate latch assembly. It is activated by the exterior handle, located in the license plate light bar, through a mechanical link rod attaching the two together. The power liftgate exterior handle switch is primarily used for manual opening of the liftgate. Activation of the switch during a automatic power "close" cycle will cause the liftgate to reverse direction. Activation of the switch during a power "open" cycle will cause the power liftgate to disengage, allowing full manual operation. The exterior handle cannot be adjusted or repaired and if damaged it must be replaced. See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Handle/Service and Repair/Exterior Handle - Removal. The power liftgate exterior handle switch cannot be adjusted or repaired and if damaged or inoperative the complete power liftgate latch assembly must be replaced. See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/Removal and Replacement/Power Liftgate Latch - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch - Installation > Page 748 Trunk / Liftgate Switch: Description and Operation Exterior Handle Switch - Removal OPERATION When the exterior liftgate handle is pulled, a mechanical linkage inside the liftgate depresses the power liftgate exterior handle switch in the power liftgate latch assembly. A hard-wired signal is then detected by the Power Liftgate Control Module. The power liftgate control module then looks at the vehicle lock status on the Controller Area Network (CAN) data bus. If the vehicle is not locked and the operating conditions are met, the power liftgate control module then applies power to the latch mounted motor, which moves the liftgate from the primary closed and latched position to the open and movable position. If the liftgate is not pulled open within seven seconds, once the latch releases, the latch will automatically cinch closed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch - Installation > Page 749 Trunk / Liftgate Switch: Description and Operation Overhead Console Switch - Description DESCRIPTION NOTE: The overhead console shown contains a combination power liftgate/power sunroof switch. Vehicles equipped with the power liftgate and no sunroof contain a single power liftgate switch only. NOTE: On vehicles equipped with both a power sunroof and power liftgate the overhead console switches are serviced together as one assembly. NOTE: Durango overhead console with Electronic Vehicle Information Center (EVIC) shown. Aspen overhead console similar. The power liftgate switch (3) is mounted in the overhead console assembly (1) between the reading lamps (2). The switch is snapped into mounting slots in the overhead console assembly. The momentary, push button-type power liftgate switch, provides a hardwired signal to the Power Liftgate Control Module. If the switch is inoperative or damaged the power liftgate/power sunroof switch assembly must be replaced. See: Service and Repair/Overhead Console Switch - Removal for the appropriate procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch - Installation > Page 750 Trunk / Liftgate Switch: Description and Operation Overhead Console Switch - Operation OPERATION Battery voltage is supplied to the power liftgate system through a fuse, located in the Integrated Power Module (IPM) assembly. When the power liftgate switch is pushed, a hardwired signal is sent to the Power Liftgate Control Module. The power liftgate control module then interprets the information to confirm safety requirements are met before applying power to the power liftgate drive unit to start a power cycle. During a power liftgate open or close cycle, if the power liftgate control module detects sufficient resistance to liftgate travel, such as an obstruction in the liftgate's path. The control module will immediately stop liftgate movement and reverse the direction of travel to the full open or closed position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Description and Operation > Page 751 Trunk / Liftgate Switch: Testing and Inspection OVERHEAD CONSOLE LIFTGATE SWITCH Diagnostic resistors are present inside the overhead console liftgate switch. These resistors are used by the power liftgate control module to determine if the switch is stuck, disconnected, shorted or otherwise damaged. Refer to the OVERHEAD CONSOLE LIFTGATE SWITCH DIAGNOSTIC TABLE to test the switch resistance. OVERHEAD CONSOLE LIFTGATE SWITCH DIAGNOSTIC TABLE NOTE: Test table readings are ± 2%. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Overhead Console Switch - Removal Trunk / Liftgate Switch: Service and Repair Overhead Console Switch - Removal REMOVAL DURANGO 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console assembly (3), See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console Removal. 3. Using trim stick C-4755 or equivalent, pry the back edge of the power liftgate switch (1) up until the two retaining tabs (2) are fully released. 4. Tilt the power liftgate switch (1) up away from the overhead console assembly (3) until the mounting tab on the opposite side of the switch releases. 5. Remove the switch from the vehicle. ASPEN 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console assembly (3), See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console Removal. 3. Using trim stick C-4755 or equivalent, pry the side edges (4) of the overhead console assembly out until the two retaining tabs on the power liftgate switch (5) are fully released. 4. Push the switch (5) out through the back of the overhead console (3). 5. Remove the switch from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Overhead Console Switch - Removal > Page 754 Trunk / Liftgate Switch: Service and Repair Overhead Console Switch - Installation INSTALLATION DURANGO 1. Position the power liftgate switch into the overhead console assembly so that the large retaining tab (2) is aligned with the large slot between the reading lamps. 2. Gently press the power liftgate switch (1) into the overhead console assembly (3) until the two small mounting tabs (2) have snapped securely into place. 3. Install the overhead console assembly (3), See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console Installation. 4. Connect the battery negative cable. 5. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes. 6. Verify power liftgate system operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. ASPEN Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Overhead Console Switch - Removal > Page 755 1. Position the power liftgate switch (5) into the overhead console assembly (3). 2. Gently press the power liftgate switch (5) into the overhead console assembly (3) until the mounting tabs have snapped securely into place (4). 3. Install the overhead console assembly (3), See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console Installation. 4. Connect the battery negative cable. 5. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes. 6. Verify power liftgate system operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Booster Vacuum Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Booster Vacuum Sensor > Page 761 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams > Booster Vacuum Sensor (HEV) (Headlamp And Dash) 4 Way Brake Booster Vacuum Sensor: Diagrams Booster Vacuum Sensor (HEV) (Headlamp And Dash) 4 Way Connector (HEV) - (HEADLAMP AND DASH) 4 WAY SENSOR-BOOSTER VACUUM (HEV) - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams > Booster Vacuum Sensor (HEV) (Headlamp And Dash) 4 Way > Page 764 Brake Booster Vacuum Sensor: Diagrams Vacuum Pressure Sensor (ESP) (Headlamp And Dash) 3 Way Connector (ESP) - (HEADLAMP AND DASH) 3 WAY SENSOR-VACUUM PRESSURE (ESP) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams > Page 765 Brake Booster Vacuum Sensor: Description and Operation DESCRIPTION The Vacuum sensor measures the available vacuum in the brake booster. In the event of a Booster failure, the ESP system offers additional brake force to the driver. Utilizing the hydraulic system of ESP, the brake line pressure is increased to achieve a higher deceleration with low pedal force Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Service and Repair > Brake Vacuum Sensor - Removal Brake Booster Vacuum Sensor: Service and Repair Brake Vacuum Sensor - Removal REMOVAL 1. Disconnect the vacuum sensor electrical connector (1). 2. Remove vacuum sensor (1) from the power brake booster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Service and Repair > Brake Vacuum Sensor - Removal > Page 768 Brake Booster Vacuum Sensor: Service and Repair Brake Vacuum Sensor - Installation INSTALLATION 1. Install vacuum sensor (1) to the power brake booster. 2. Connect wiring harness (1) connector to vacuum sensor. 3. Perform Verification Test and clear any faults. See: Brakes and Traction Control/Testing and Inspection. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 772 Brake Fluid Level Sensor/Switch: Diagrams Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-BRAKE FLUID LEVEL - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Brake Pedal Angle Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Brake Pedal Angle Sensor > Page 777 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Brake Pedal Angle Sensor (Headlamp And Dash) 6 Way Braking Sensor/Switch: Diagrams Brake Pedal Angle Sensor (Headlamp And Dash) 6 Way Connector - (HEADLAMP AND DASH) 6 WAY SENSOR-BRAKE PEDAL ANGLE - (HEADLAMP AND DASH) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Brake Pedal Angle Sensor (Headlamp And Dash) 6 Way > Page 780 Braking Sensor/Switch: Diagrams Brake Pedal Pressure Sensor (HEV) (Headlamp And Dash) 3 Way Connector (HEV) - (HEADLAMP AND DASH) 3 WAY SENSOR-BRAKE PEDAL PRESSURE (HEV) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams > Dynamics Sensor (ESP) (Instrument Panel) 4 Way Lateral Accelerometer: Diagrams Dynamics Sensor (ESP) (Instrument Panel) 4 Way Connector (ESP) - (INSTRUMENT PANEL) 4 WAY SENSOR-DYNAMICS (ESP) - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams > Dynamics Sensor (ESP) (Instrument Panel) 4 Way > Page 786 Lateral Accelerometer: Diagrams Dynamics Sensor (HEV) (Instrument Panel) 6 Way Connector (HEV) - (INSTRUMENT PANEL) 6 WAY SENSOR-DYNAMICS (HEV) - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Description and Operation > Dynamics Sensor - Description Lateral Accelerometer: Description and Operation Dynamics Sensor - Description DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (2). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor (2) must be replaced when necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Description and Operation > Dynamics Sensor - Description > Page 789 Lateral Accelerometer: Description and Operation G Sensor - Description DESCRIPTION The G-sensor is located only inside the ABS controller 4x4 only. The sensor is not a separate serviceable part from the antilock brake module (ABM). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal Lateral Accelerometer: Service and Repair Dynamics Sensor - Removal REMOVAL 1. Remove the center console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Removal. 2. Disconnect electrical connector (3) from the dynamics sensor (2). 3. Remove the two nuts (1) securing the sensor to the floor. 4. Remove the sensor (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 792 Lateral Accelerometer: Service and Repair Dynamics Sensor - Installation INSTALLATION 1. Install the dynamics sensor (2) on the studs (4) to the vehicle. NOTE: Make sure the electrical connector is facing toward the rear of the vehicle. 2. Connect the electrical connector (3) to the sensor (2). 3. Install the two retaining nuts (1) and tighten to 6 Nm (53 in. lbs.). 4. Install the floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Installation. 5. Perform the ABS verification test with the scan tool. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 796 Parking Brake Warning Switch: Diagrams Connector - (BODY) 1 WAY SWITCH-PARKING BRAKE - (BODY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description > Page 799 Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Page 800 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. See: Brakes and Traction Control/Testing and Inspection . If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 803 Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 807 Steering Angle Sensor: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SENSOR-STEERING ANGLE - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 808 Steering Angle Sensor: Description and Operation DESCRIPTION NOTE: Steering angle sensor is part of the airbag clockspring and is not serviced separately from the clockspring. The steering angle sensor is used to measure the driver intended path in the ESP system. Based on the deviation between steering wheel input and the Yaw Rate signal from the dynamic sensor, ESP can be activated. The SAS should be mounted correctly to ensure that the system functions properly and there are not inadvertent activations. Any replacement of the steering angle sensor requires that the ABS verification test be performed. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Service and Repair > Removal Steering Angle Sensor: Service and Repair Removal REMOVAL NOTE: Steering angle sensor is part of the airbag clockspring and is not serviced separately from the clockspring. 1. For removal of the steering angle sensor See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement/Clockspring - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Service and Repair > Removal > Page 811 Steering Angle Sensor: Service and Repair Installation INSTALLATION NOTE: Steering angle sensor is part of the airbag clockspring and is not serviced separately from the clockspring. 1. For installation of the steering angle sensor See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement/Clockspring - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 815 Traction Control Switch: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SWITCH-TRACTION CONTROL - (INSTRUMENT PANEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations > Page 819 Vacuum Brake Booster Diaphragm Position Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 3 WAY SENSOR-BOOSTER TRAVEL (HEV) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Description DESCRIPTION The travel sensor (7) is mounted on power brake booster (1) below and to the left of the master cylinder, and has one electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description > Page 822 Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Operation OPERATION The travel sensor is a three-wire potentiometer that varies the voltage output as the position of the booster diaphragm changes. The RBS module uses the position information to determine the amount of booster movement and hydraulic brake application. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor - Removal REMOVAL 1. Disconnect the electrical connector (2) from the travel sensor (1). NOTE: The retainer clip does not need to be removed, only pushed up slightly to disengage the tabs on the sensor. 2. Using a small screw driver (4) or another suitable tool, push up on the retainer clip (2) and pull the travel sensor (3) from the power brake booster (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal > Page 825 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor Installation INSTALLATION NOTE: When replacing the travel sensor, the Anti-Lock Brake Module (ABM) must be initialized using the scan tool. To initialize the ABM perform the ABS VERIFICATION TEST - HEV. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test . NOTE: Verify that the surface is clean, the old O-ring is removed, and the new O-ring is properly positioned on the sensor. 1. With a slight twisting motion, push the travel sensor (3) into the power brake booster (1). There should be a slight snapping sound as the retainer clip (3) seats into position. 2. Verify that the travel sensor retainer clip (3) snapped into place. 3. Connect the electrical connector (2) to the travel sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 830 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 831 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 832 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT FRONT - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way > Page 835 Wheel Speed Sensor: Diagrams Left Rear Wheel Speed Sensor (Chassis) 2 Way Connector - (CHASSIS) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT REAR - (CHASSIS) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way > Page 836 Wheel Speed Sensor: Diagrams Right Front Wheel Speed Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT FRONT - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way > Page 837 Wheel Speed Sensor: Diagrams Right Rear Wheel Speed Sensor (Chassis) 2 Way Connector - (CHASSIS) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT REAR - (CHASSIS) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 838 Wheel Speed Sensor: Description and Operation OPERATION The sensors convert wheel speed into a digital signal. The ABM sends 12 volts to the sensors. The sensor has an internal hall sensor that alters the voltage and amperage of the signal circuit. This voltage and amperage is changed by magnetic induction when the toothed tone wheel passes the wheel speed sensor. This digital signal is sent to the ABM. The ABM measures the voltage and amperage of the digital signal for each wheel. The signal strength is affected by the distance between the Sensor and the tone ring. If the "Air Gap" between the WSS and the tone ring/wheel is too large, the WSS signal can drop out at low speed, (below 40 mph) and can cause an ABS activation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Removal Front REMOVAL 1. Remove the front rotor See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 2. Remove the wheel speed sensor mounting bolt (1) from the hub (3). 3. Remove the wheel speed sensor (2) from the hub (3). 4. Remove the wiring from the clips and disconnect the electrical connector. Rear REMOVAL 1. Raise the vehicle on a hoist. 2. Disconnect the wheel speed sensor electrical connector (3). 3. Remove the mounting bolt (1) from the sensor (4). 4. Remove the sensor (4) from the brake caliper adapter (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 841 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Installation Front INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor (2) to the hub (3). 3. Install the wheel speed sensor mounting bolt (1) to the hub (3). Tighten the bolt to 21 Nm (190 in. lbs.). 4. Install the front rotor and brake caliper assembly See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. Rear INSTALLATION 1. Insert the wheel speed sensor (4) in the brake caliper adapter (2). 2. Install the sensor mounting bolt (1) and tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical wiring connector (3) to the sensor (4). 4. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams > Dynamics Sensor (ESP) (Instrument Panel) 4 Way Yaw Rate Sensor: Diagrams Dynamics Sensor (ESP) (Instrument Panel) 4 Way Connector (ESP) - (INSTRUMENT PANEL) 4 WAY SENSOR-DYNAMICS (ESP) - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams > Dynamics Sensor (ESP) (Instrument Panel) 4 Way > Page 847 Yaw Rate Sensor: Diagrams Dynamics Sensor (HEV) (Instrument Panel) 6 Way Connector (HEV) - (INSTRUMENT PANEL) 6 WAY SENSOR-DYNAMICS (HEV) - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Description and Operation > Dynamics Sensor - Description Yaw Rate Sensor: Description and Operation Dynamics Sensor - Description DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (2). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor (2) must be replaced when necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Description and Operation > Dynamics Sensor - Description > Page 850 Yaw Rate Sensor: Description and Operation G Sensor - Description DESCRIPTION The G-sensor is located only inside the ABS controller 4x4 only. The sensor is not a separate serviceable part from the antilock brake module (ABM). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal Yaw Rate Sensor: Service and Repair Dynamics Sensor - Removal REMOVAL 1. Remove the center console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Removal. 2. Disconnect electrical connector (3) from the dynamics sensor (2). 3. Remove the two nuts (1) securing the sensor to the floor. 4. Remove the sensor (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 853 Yaw Rate Sensor: Service and Repair Dynamics Sensor - Installation INSTALLATION 1. Install the dynamics sensor (2) on the studs (4) to the vehicle. NOTE: Make sure the electrical connector is facing toward the rear of the vehicle. 2. Connect the electrical connector (3) to the sensor (2). 3. Install the two retaining nuts (1) and tighten to 6 Nm (53 in. lbs.). 4. Install the floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Installation. 5. Perform the ABS verification test with the scan tool. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 859 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 860 Coolant Temperature Sensor/Switch (For Computer): Diagrams Connector - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Hybrid Drive Coolant Temperature Sensor > Component Information > Diagrams Hybrid Drive Coolant Temperature Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 2 WAY SENSOR-TPIM COOLANT TEMPERATURE (HEV) - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Hybrid Drive Coolant Temperature Sensor > Component Information > Diagrams > Page 864 Hybrid Drive Coolant Temperature Sensor: Description and Operation TPIM COOLING SYSTEM TEMPERATURE SENSOR The TPIM cooling system temperature sensor (2) is used to sense the coolant temperature. The sensor (2) is located in the combination Transmission/TPIM cooler. The coolant sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. As the coolant temperature increases, resistance (voltage) in the sensor decreases. As the temperature decreases, resistance (voltage) in the sensor increases. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Hybrid Drive Coolant Temperature Sensor > Component Information > Service and Repair > TPIM Cooling System Temperature Sensor - Removal Hybrid Drive Coolant Temperature Sensor: Service and Repair TPIM Cooling System Temperature Sensor - Removal TPIM COOLING SYSTEM TEMPERATURE SENSOR WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform HEV specific high voltage power down and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the negative battery cable. CAUTION: Disconnecting the 12 V battery from the vehicle within two minutes of the last ignition key transition from Off to Run may cause a Battery Pack Control Module (BPCM) State Of Charge (SOC) mismatch. 3. Raise and support the vehicle. 4. Drain the TPIM cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/TPIM Cooling System Draining NOTE: DO NOT spill coolant on electrical connections or connectors. 5. Disconnect the temperature sensor electrical connector. 6. Remove the temperature sensor (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Hybrid Drive Coolant Temperature Sensor > Component Information > Service and Repair > TPIM Cooling System Temperature Sensor - Removal > Page 867 Hybrid Drive Coolant Temperature Sensor: Service and Repair TPIM Cooling System Temperature Sensor - Installation TPIM COOLING SYSTEM TEMPERATURE SENSOR WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Install the temperature sensor (2) into the Transmission/TPIM cooler (1). 2. Tighten the sensor to 20 Nm (15 ft. lbs.). 3. Connect negative battery cable. 4. Perform HEV specific high voltage power up and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 5. Fill the TPIM cooling system and check for leaks. See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/TPIM Cooling System Filling Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Left Speed Control Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Left Speed Control Switch > Page 873 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Left Speed Control Switch (Steering Wheel) 3 Way Cruise Control Switch: Diagrams Left Speed Control Switch (Steering Wheel) 3 Way Connector - (STEERING WHEEL) 3 WAY SWITCH-SPEED CONTROL-LEFT - (STEERING WHEEL) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Left Speed Control Switch (Steering Wheel) 3 Way > Page 876 Cruise Control Switch: Diagrams Right Speed Control Switch (Steering Wheel) 3 Way Connector - (STEERING WHEEL) 3 WAY SWITCH-SPEED CONTROL-RIGHT - (STEERING WHEEL) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Speed Control Switch - Description Cruise Control Switch: Description and Operation Speed Control Switch - Description DESCRIPTION Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the Owner's Manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Speed Control Switch - Description > Page 879 Cruise Control Switch: Description and Operation Speed Control Switch - Operation OPERATION When speed control is selected by depressing the ON, OFF switch, the PCM allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 (56.2kph) and 85 mph (136.8kph). In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph (16 kph) per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph (16 kph) per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph (32.1 kph) of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's RAM when the ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph (3.2 kph) for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's ON, OFF input, and the battery voltage to the brake switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal Cruise Control Switch: Service and Repair Speed Control Switch - Removal REMOVAL WARNING: Before attempting to diagnose, remove or install any airbag system or related steering wheel and steering column components you must first disconnect and isolate the negative (ground) battery cable. Wait 2 minutes for system capacitor to discharge before further system service. Failure to do so could result in accidental deployment and possible personal injury. 1. Disconnect and isolate negative battery cable from battery. 2. Remove airbag module. 3. Unplug electrical connector. 4. Remove speed control switch mounting screw (1) and remove switch from steering wheel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal > Page 882 Cruise Control Switch: Service and Repair Speed Control Switch - Installation INSTALLATION 1. Position switch to steering wheel. 2. Install switch mounting screw and tighten to 15 in. lbs. (1.7 Nm). 3. Plug electrical connector into switch. 4. Install airbag module. 5. Connect negative battery cable to battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations > Page 886 Vacuum Brake Booster Diaphragm Position Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 3 WAY SENSOR-BOOSTER TRAVEL (HEV) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Description DESCRIPTION The travel sensor (7) is mounted on power brake booster (1) below and to the left of the master cylinder, and has one electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description > Page 889 Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Operation OPERATION The travel sensor is a three-wire potentiometer that varies the voltage output as the position of the booster diaphragm changes. The RBS module uses the position information to determine the amount of booster movement and hydraulic brake application. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor - Removal REMOVAL 1. Disconnect the electrical connector (2) from the travel sensor (1). NOTE: The retainer clip does not need to be removed, only pushed up slightly to disengage the tabs on the sensor. 2. Using a small screw driver (4) or another suitable tool, push up on the retainer clip (2) and pull the travel sensor (3) from the power brake booster (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal > Page 892 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor Installation INSTALLATION NOTE: When replacing the travel sensor, the Anti-Lock Brake Module (ABM) must be initialized using the scan tool. To initialize the ABM perform the ABS VERIFICATION TEST - HEV. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test . NOTE: Verify that the surface is clean, the old O-ring is removed, and the new O-ring is properly positioned on the sensor. 1. With a slight twisting motion, push the travel sensor (3) into the power brake booster (1). There should be a slight snapping sound as the retainer clip (3) seats into position. 2. Verify that the travel sensor retainer clip (3) snapped into place. 3. Connect the electrical connector (2) to the travel sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 897 Oil Pressure Sender: Diagrams Connector - (ENGINE) 2 WAY SWITCH-OIL PRESSURE - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 901 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 902 Oil Pressure Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-OIL PRESSURE - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 903 Oil Pressure Sensor: Description and Operation DESCRIPTION The oil pressure sensor uses the following three circuits: - Signal circuit to the PCM - Sensor ground circuit through the PCM - 5 volt reference circuit from the PCM The oil pressure sensor returns a voltage signal back to the PCM with reference to oil pressure. Ground for the sensor is supplied by the PCM. The oil pressure sensor is located on the right side of the engine block. The sensor screws into the engines main oil gallery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Oil Pressure Sensor - Removal Oil Pressure Sensor: Service and Repair Oil Pressure Sensor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the High Voltage Power Down Procedure . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Raise and support the vehicle. 3. Disconnect the oil pressure sensor electrical connector (1). 4. Remove the oil pressure sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Oil Pressure Sensor - Removal > Page 906 Oil Pressure Sensor: Service and Repair Oil Pressure Sensor - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions NOTE: Apply Mopar(R) Thread Sealant with PTFE to the sensor threads before installing into the engine block. 1. Install the oil pressure sensor (1). 2. Connect the oil pressure sensor electrical connector (1). 3. Lower the vehicle. 4. Perform the High Voltage Power Up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Fuel Tank Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Fuel Tank Pressure Sensor > Page 911 Oil Temperature Sensor/Switch: Locations Engine Oil Temperature Sensor (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Fuel Tank Pressure Sensor > Page 912 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Diagrams > Engine Oil Temperature Sensor (5.7L) (Engine) 2 Way Oil Temperature Sensor/Switch: Diagrams Engine Oil Temperature Sensor (5.7L) (Engine) 2 Way Connector (5.7L) - (ENGINE) 2 WAY SENSOR-ENGINE OIL TEMPERATURE (5.7L) - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Diagrams > Engine Oil Temperature Sensor (5.7L) (Engine) 2 Way > Page 915 Oil Temperature Sensor/Switch: Diagrams Fuel Tank Pressure Sensor (Chassis) 3 Way Connector - (CHASSIS) 3 WAY SENSOR-FUEL TANK PRESSURE - (CHASSIS) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Diagrams > Page 916 Oil Temperature Sensor/Switch: Description and Operation DESCRIPTION The oil temperature sensor uses the following two circuits: - Signal circuit to the PCM - Ground circuit from the PCM The oil temperature sensor is a Negative Thermal Coefficient sensor. The resistance of the sensor changes as oil temperature changes. This results in different output voltages back to the PCM. The oil temperature sensor is located on the right side of the engine block. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Oil Temperature Sensor - Removal Oil Temperature Sensor/Switch: Service and Repair Oil Temperature Sensor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the High Voltage Power Down Procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Raise and support the vehicle. 3. Disconnect the oil temperature sensor electrical connector (1). 4. Remove the oil temperature sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Oil Temperature Sensor - Removal > Page 919 Oil Temperature Sensor/Switch: Service and Repair Oil Temperature Sensor - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions NOTE: Apply Mopar(R) Thread Sealant with PTFE to the sensor threads before installing into the engine block. 1. Install the oil temperature sensor (1). 2. Connect the oil temperature sensor electrical connector (1). 3. Lower the vehicle. 4. Perform the High Voltage Power Up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Ambient Air Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Ambient Air Temperature Sensor > Page 925 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 926 Ambient Temperature Sensor / Switch HVAC: Diagrams Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-AMBIENT AIR TEMPERATURE - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Front Ambient Temperature Sensor - Description Ambient Temperature Sensor / Switch HVAC: Description and Operation Front Ambient Temperature Sensor - Description DESCRIPTION The ambient air temperature sensor is a variable resistor that monitors the air temperature outside of the vehicle. The ambient air temperature sensor is mounted onto the inside of the front bumper beam and its data is used by the heating-A/C system to maintain optimum cabin temperature levels. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Front Ambient Temperature Sensor - Description > Page 929 Ambient Temperature Sensor / Switch HVAC: Description and Operation Front Ambient Temperature Sensor - Operation OPERATION The ambient air temperature sensor is a variable resistor that operates on a ground circuit and a 5-volt reference signal circuit sent by the front control module (FCM) through a two-wire lead and connector of the vehicle wire harness. The ambient air temperature sensor changes its internal resistance in response to changes in the outside air temperature, which either increases or decreases the reference signal voltage read by the FCM. The FCM converts and broadcasts the sensor data over the controller area network (CAN) B bus, where it is read by the A/C-heater control and other various vehicle control modules. The ambient air temperature sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The ambient air temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged See: Sensors and Switches - Instrument Panel/Outside Temperature Display Sensor/Service and Repair/Ambient Temperature Sensor - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed Evaporator Temperature Sensor / Switch: Customer Interest A/C - No A/C After Long Trip With Blower On Low Speed NUMBER: 24-004-10 GROUP: Heating & Air Conditioning DATE: April 7, 2010 SUBJECT: No A/C Or Evaporator Freeze Up On Long Trips With Blower In Low Speed Position OVERVIEW: This bulletin involves adding a resistor 470 ohm resistor in the evaporator temperature sensor signal circuit. MODELS: 2004-2009 (HB) Durango 2007-2009 (HG) Aspen NOTE: This bulletin applies to all HB/HG vehicles with A/C (sales code HAA or HAB or HAF). This bulletin does not cover the 2009 HG HEV vehicle. SYMPTOM/CONDITION: The customers may experience poor A/C, little to no A/C operation or reduced airflow from the instrument panel vents. This condition often occurs after a extended drive cycle (greater that 2 hours) with the A/C on and the blower speed is set to the low position. Once the vehicle is shut off or the A/C is turned off for approximately 2 hours the A/C will operate normally. Adding the resistor to the evaporator temperature sensor signal wire allows the A/C Compressor to cycle at a higher temperature more frequently to avoid this condition. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all A/C systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and disconnect the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 - Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Removal Procedures. 2. Using the wiring diagrams available in DealerCONNECT/TechCONNECT locate the evaporator temperature sensor signal wire. Cavity 10 of the C2 black 12 - way connector for ATC systems. Cavity 2 of 20 - way black C1 connector for MTC systems. 3. Measure 76mm (3 inches) down from end of ATC/MTC connector and cut the evaporator temperature sensor signal wire. 4. Using the 2 splice crimps and 2 wire shrink wraps from resistor kit p/n 68064996AA splice in the 470 ohm resistor. Follow the detailed wiring procedures available in DealerCONNECT/TechCONNECT, Refer To the Wiring Tab > 8W-01 Wiring Diagram Information > Wire > Standard Procedure. NOTE: Be sure to use the splice crimps and shrink wrap on wires and resistor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed > Page 938 5. Install the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Installation Procedures. 6. Using the wiTECH(TM) or StarSCAN(R) erase all DTC. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed Evaporator Temperature Sensor / Switch: All Technical Service Bulletins A/C - No A/C After Long Trip With Blower On Low Speed NUMBER: 24-004-10 GROUP: Heating & Air Conditioning DATE: April 7, 2010 SUBJECT: No A/C Or Evaporator Freeze Up On Long Trips With Blower In Low Speed Position OVERVIEW: This bulletin involves adding a resistor 470 ohm resistor in the evaporator temperature sensor signal circuit. MODELS: 2004-2009 (HB) Durango 2007-2009 (HG) Aspen NOTE: This bulletin applies to all HB/HG vehicles with A/C (sales code HAA or HAB or HAF). This bulletin does not cover the 2009 HG HEV vehicle. SYMPTOM/CONDITION: The customers may experience poor A/C, little to no A/C operation or reduced airflow from the instrument panel vents. This condition often occurs after a extended drive cycle (greater that 2 hours) with the A/C on and the blower speed is set to the low position. Once the vehicle is shut off or the A/C is turned off for approximately 2 hours the A/C will operate normally. Adding the resistor to the evaporator temperature sensor signal wire allows the A/C Compressor to cycle at a higher temperature more frequently to avoid this condition. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all A/C systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and disconnect the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 - Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Removal Procedures. 2. Using the wiring diagrams available in DealerCONNECT/TechCONNECT locate the evaporator temperature sensor signal wire. Cavity 10 of the C2 black 12 - way connector for ATC systems. Cavity 2 of 20 - way black C1 connector for MTC systems. 3. Measure 76mm (3 inches) down from end of ATC/MTC connector and cut the evaporator temperature sensor signal wire. 4. Using the 2 splice crimps and 2 wire shrink wraps from resistor kit p/n 68064996AA splice in the 470 ohm resistor. Follow the detailed wiring procedures available in DealerCONNECT/TechCONNECT, Refer To the Wiring Tab > 8W-01 Wiring Diagram Information > Wire > Standard Procedure. NOTE: Be sure to use the splice crimps and shrink wrap on wires and resistor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed > Page 944 5. Install the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Installation Procedures. 6. Using the wiTECH(TM) or StarSCAN(R) erase all DTC. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Page 945 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Page 946 Evaporator Temperature Sensor / Switch: Diagrams Connector - 2 WAY SENSOR-EVAPORATOR TEMPERATURE - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Front Evaporator Temperature Sensor - Description Evaporator Temperature Sensor / Switch: Description and Operation Front Evaporator Temperature Sensor - Description DESCRIPTION The evaporator temperature sensor (1) is an electrical thermistor located within a molded plastic case that is inserted into the HVAC housing (2) to measure the temperature of the conditioned air downstream of the A/C evaporator (3). Two terminals within the connector receptacle connect the sensor to the vehicle electrical system through a wire lead and connector of the HVAC wire harness. NOTE: Cutaway of typical HVAC housing shown for clarity in illustration. The external location of the evaporator temperature sensor allows the sensor to be removed or installed without disturbing the refrigerant in the A/C system. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Front Evaporator Temperature Sensor - Description > Page 949 Evaporator Temperature Sensor / Switch: Description and Operation Front Evaporator Temperature Sensor - Operation OPERATION The evaporator temperature sensor monitors the temperature of the conditioned air downstream of the A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. On gasoline engine equipped models, the A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature and that conditions are correct to broadcast an A/C request message on the Controller Area Network (CAN) B bus, where it is read by the Front Control Module (FCM). The FCM then requests the Powertrain Control Module (PCM) to cycle the A/C compressor clutch as necessary over the CAN C bus. On Hybrid Electric Vehicle (HEV) models, the A/C-heater control calculates an evaporator temperature target based on A/C load. This target temperature is compared with the actual evaporator temperature sensor value. Based on this comparison, the A/C-heater control sends out a compressor target RPM speed over the CAN B bus to the FCM. The FCM then ports the target message to the electric A/C compressor over the CAN C bus. If the A/C-heater control does not receive the electric A/C compressor messages, a Diagnostic Trouble Code (DTC) will be set. The evaporator temperature sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The evaporator temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Front Evaporator Temperature Sensor - Removal Evaporator Temperature Sensor / Switch: Service and Repair Front Evaporator Temperature Sensor - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage during this service procedure. 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 3. Disconnect the HVAC wire harness connector (1) from the evaporator temperature sensor (2) located on the top of the HVAC housing (3) near the blend door actuator (4). 4. Remove the evaporator temperature sensor from the HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Front Evaporator Temperature Sensor - Removal > Page 952 Evaporator Temperature Sensor / Switch: Service and Repair Front Evaporator Temperature Sensor - Installation INSTALLATION 1. Install the evaporator temperature sensor (2) into the opening in the HVAC housing (3) near the blend door actuator (4). 2. Connect the HVAC wire harness connector (1) to the evaporator temperature sensor. 3. Install the instrument panel assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Installation. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Locations > Page 956 Humidity Sensor: Diagrams Connector - (MIRROR JUMPER) 4 WAY SENSOR-HUMIDITY - (MIRROR JUMPER) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Description and Operation > Humidity Sensor - Description Humidity Sensor: Description and Operation Humidity Sensor - Description DESCRIPTION A humidity sensor (1) is used on HEV models to detect humidity levels inside the vehicle to optimize the dehumidifying effect of the A/C system, which reduces electronic air conditioning (EAC) power consumption. The humidity sensor attaches to the interior rear view mirror base (2) and is connected to the vehicle electrical system by a wire lead and connector of the mirror wire harness (3). The humidity sensor can be serviced from the interior rear view mirror without the use of any special tools. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Description and Operation > Humidity Sensor - Description > Page 959 Humidity Sensor: Description and Operation Humidity Sensor - Operation OPERATION The humidity sensor detects humidity, dew point, windshield temperature and infrared sensor data and sends this information to the Hybrid Gateway Module (HGM) via a Local Interconnect Network (LIN) bus connection. The HGM then sends the message via the Controller Area Network (CAN) C bus to the Front Control Module (FCM), which ports the message to the A/C-heater control over the CAN B bus. If the humidity sensor message is not received by the A/C-heater control, the evaporator logic will be disabled, the evaporator target will be set to 3.3° C (38° F) and a Diagnostic Trouble Code (DTC) will set. The information the A/C-heater control receives from the humidity sensor can be viewed using a scan tool. The humidity sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The humidity sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Service and Repair > Humidity Sensor - Removal Humidity Sensor: Service and Repair Humidity Sensor - Removal REMOVAL 1. Disconnect and isolate the negative battery cable 2. Remove the inside rear view mirror from the front glass See: Body and Frame/Mirrors/Service and Repair/Interior Rearview Mirror - Removal 3. Disconnect the retaining tabs that secure the humidity sensor (1) to the mirror base (2) and slide the sensor off the base. 4. Disconnect the wire harness connector (3) from the humidity sensor and remove the sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Service and Repair > Humidity Sensor - Removal > Page 962 Humidity Sensor: Service and Repair Humidity Sensor - Installation INSTALLATION 1. Connect the mirror wire harness (3) to the humidity sensor (1). 2. Position the humidity sensor onto the rear view mirror base (2) and engage the retaining tabs. Make sure the retaining tabs are fully engaged. 3. Install the interior rear view mirror See: Body and Frame/Mirrors/Service and Repair/Interior Rearview Mirror - Installation. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 966 Refrigerant Pressure Sensor / Switch: Diagrams Connector - (HEADLAMP AND DASH) 4 WAY TRANSDUCER-A/C PRESSURE - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Front A/C Pressure Transducer - Description Refrigerant Pressure Sensor / Switch: Description and Operation Front A/C Pressure Transducer Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Front A/C Pressure Transducer - Description > Page 969 Refrigerant Pressure Sensor / Switch: Description and Operation Front A/C Pressure Transducer Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the discharge line. The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. A Schrader-type valve in the discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. On gasoline engine models, the Front Control Module (FCM) provides a five volt reference signal to the A/C pressure transducer, then monitors the output voltage of the A/C pressure transducer on a sensor return circuit to determine refrigerant pressure. The FCM broadcasts a refrigerant pressure message to the Powertrain Control Module (PCM), which is programmed to respond to the A/C pressure transducer and other sensor inputs by controlling the operation of the A/C compressor clutch and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM will disengage the A/C compressor clutch when high side pressure rises above 3275 kPa (475 psi) and re-engage the clutch when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer will also disengage the A/C compressor clutch if the high side pressure drops below 193 kPa (28 psi) and will re-engage the clutch when the high side pressure rises above 234 kPa (34 psi). If the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. The A/C pressure transducer message to the PCM will also prevent the A/C compressor clutch from engaging when ambient temperatures are below about 4.5° C (40° F) due to the pressure/temperature relationship of the refrigerant. See Electric A/C Condenser Cooling Fan Switch Point charts for condenser cooling fan on/off pressures. On Hybrid Electric Vehicle (HEV) models, the A/C-heater control receives the A/C pressure transducer signal from the FCM. The A/C-heater control will then do the following based on head pressure: - <= 2.0 Bar (29 psi) Disable compressor for low charge - > 2.5 Bar (36 psi) Enable compressor - >= 28 Bar (406 psi) Reduce compressor speed to reduce head pressure - >= 29.5 Bar (427 psi) Shut down compressor due to high head pressure - < 21 Bar (306 psi) Re-enable compressor if previously shut down The A/C pressure transducer is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if inoperative or damaged. ELECTRIC A/C CONDENSER COOLING FAN SWITCH POINT - 3.7L/4.7L/5.7L GAS ENGINES ELECTRIC A/C CONDENSER COOLING FAN SWITCH POINT - 5.7L HEV ENGINE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Front A/C Pressure Transducer - Removal Refrigerant Pressure Sensor / Switch: Service and Repair Front A/C Pressure Transducer Removal REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2). 3. Remove the A/C pressure transducer from the A/C discharge line (3). 4. Remove the O-ring seal (4) from the discharge line fitting and discard. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Front A/C Pressure Transducer - Removal > Page 972 Refrigerant Pressure Sensor / Switch: Service and Repair Front A/C Pressure Transducer Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the discharge line fitting. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Infrared Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Infrared Sensor > Page 977 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Infrared Sensor (Headliner) 4 Way Solar Sensor: Diagrams Infrared Sensor (Headliner) 4 Way Connector - (HEADLINER) 4 WAY SENSOR-INFRARED - (HEADLINER) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Infrared Sensor (Headliner) 4 Way > Page 980 Solar Sensor: Diagrams Sun Sensor (Instrument Panel) 4 Way Connector - (INSTRUMENT PANEL) 4 WAY SENSOR-SUN - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description Solar Sensor: Description and Operation Infrared Temperature Sensor - Description DESCRIPTION The infrared sensor consists of an infrared transducer (1) located in the overhead console. The infrared sensor is used only on models equipped with the automatic temperature control (ATC) heater-A/C system. The infrared transducer is contained within a black molded plastic housing (2) with an integral wire connector receptacle (3). The integral mounting tab (4) allows the infrared sensor to be secured with one screw to the overhead console. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 983 Solar Sensor: Description and Operation Infrared Temperature Sensor - Operation OPERATION The infrared sensor detects thermal radiation emitted by the front seat occupants and surroundings and converts its data into a linear pulse width modulated (PWM) output signal, which is sent to the compass temperature module (EOM) through a two-wire lead and connector of the headliner wire harness. The EOM sends a message over the controller area network (CAN) B bus where it is read by the automatic temperature control (ATC) A/C-heater control. The ATC A/C-heater control uses the infrared sensor data as one of the inputs necessary to automatically control the interior cabin temperature level. By using thermal radiation (surface temperature) measurement, rather than an air temperature measurement, the ATC heating-A/C system is able to adjust itself to the comfort level as perceived by the occupants. This allows the ATC system to compensate for other ambient conditions affecting comfort levels, such as solar heat gain or evaporative heat loss. The ATC system logic responds to the infrared sensor message by calculating and adjusting the air flow temperature and air flow rate needed to properly obtain and maintain the selected comfort level temperature of the occupants. The EOM continually monitors the infrared sensor circuits, and will store a diagnostic trouble code (DTC) for any problem it detects. The infrared sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The infrared sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 984 Solar Sensor: Description and Operation Sun Sensor - Description DESCRIPTION NOTE: Typical sun sensor assembly shown. The automatic temperature control (ATC) heating-A/C system uses a sun sensor assembly (1) to measure sun light intensity. The sun sensor assembly incorporates two sun sensors (2) within a molded plastic case which is mounted to the instrument panel and a clear lens (3) that protrudes through the defroster grille. The wire harness receptacle (4) connects the sun sensors to the vehicle electrical system through a wire lead and connector of the instrument panel wire harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 985 Solar Sensor: Description and Operation Sun Sensor - Operation OPERATION The ATC dual-zone heating-A/C system uses two sun sensors to balance the system in response to side-to-side variations in sun light intensity. Passengers in sun and shadow require different functional settings because they experience very different temperatures. The sun sensor assembly provides data to the A/C heater control to help determine proper mode and blend-air door positions and blower motor speeds. The sun sensors are not thermistor type sensors, but rather photo diodes. For this reason the sun sensors responds to sun light intensity rather than temperature. The sun sensor assembly is also used to sense day and night conditions for automatic headlight control, if equipped. The sun sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The sun sensor assembly cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Page 986 Solar Sensor: Testing and Inspection SUN SENSOR WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible severe or fatal injury. The sun sensor assembly is located so that the sun rays will hit the sensors in the same way that it will hit the driver and the passenger. It is important that the area in front of the sun sensor assembly be unobstructed. Check for the following: - Windshield wipers are properly adjusted. - Defroster grille and sun sensor is properly installed. The sun sensor lens should protrude above the defroster grille. - Any stickers on the windshield are not directly in front of the sun sensor. - Any items laying on top of the instrument panel are not covering the sun sensor. If the vehicle exhibits a lack of passenger comfort in sunny weather such as in the early afternoon, inspect the position of the sun sensor assembly. The sun sensor lens should protrude above the defroster grille to insure proper operation. If the sun sensor is not properly positioned, perform the following procedure: 1. Confirm that the defroster grille is properly installed. If not, repair as required. 2. Remove the defroster grille and verify that the sun sensor is properly installed to the defroster grill See: Service and Repair/Sun Sensor Installation. 3. Reinstall the defroster grille. The A/C-heater control continually monitors the sun sensor circuits and will store diagnostic trouble codes (DTCs) for any problem it detects. The sun sensor can be tested in the vehicle with a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal Solar Sensor: Service and Repair Infrared Temperature Sensor - Removal REMOVAL NOTE: Typical overhead console shown. Infrared sensor location may vary. 1. Disconnect and isolate the negative battery cable. 2. Remove the overhead console (2) and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Remove the screw (3) that secures the infrared sensor (1) to the overhead console. 4. Remove the infrared sensor from the overhead console. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 989 Solar Sensor: Service and Repair Infrared Temperature Sensor - Installation INSTALLATION NOTE: Typical overhead console shown. Infrared sensor location may vary. 1. Position the infrared sensor (1) onto the overhead console (2). 2. Install the screw (3) that secures the infrared sensor to the overhead console. Tighten the screw to 2 Nm (17 in. lbs). 3. Install the overhead console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Installation. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 990 Solar Sensor: Service and Repair Sun Sensor - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the defroster grille (2) from the top of the instrument panel See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille - Removal. 3. Disconnect the wire harness connector (3) from the sun sensor assembly (1). 4. Remove the screw (4) that secures the sun sensor to the bottom of the defroster grill and remove the sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 991 Solar Sensor: Service and Repair Sun Sensor - Installation INSTALLATION 1. Position the sun sensor assembly (1) to the bottom of the defroster grill (4) and install the retaining screw (4). Tighten the screw securely. 2. Connect the wiring harness connector (3) to the sun sensor assembly. 3. Install the defroster grille See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille - Installation. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Battery Current Sensor, Hybrid Drive > Component Information > Service and Repair > High Voltage Current Sensor - Removal Battery Current Sensor: Service and Repair High Voltage Current Sensor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Remove the high voltage battery cover See: Hybrid Drive Systems/Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Removal. 2. Remove the terminal block cover assembly. 3. Remove the four side shield bolts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Battery Current Sensor, Hybrid Drive > Component Information > Service and Repair > High Voltage Current Sensor - Removal > Page 997 4. Remove the two current sensor mounting bolts. 5. Remove the contactor terminal nut (1). 6. Slide the high voltage cable through the current sensor. 7. Install the HV Battery Cable Terminal Cover 10084 on the positive high voltage line. 8. Disconnect the connector from the bottom of the current sensor and remove. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Battery Current Sensor, Hybrid Drive > Component Information > Service and Repair > High Voltage Current Sensor - Removal > Page 998 Battery Current Sensor: Service and Repair High Voltage Current Sensor - Installation INSTALLATION 1. Connect the connector to the bottom of the current sensor. 2. Remove the HV Battery Cable Terminal Cover 10084 from the positive high voltage line. 3. Slide the high voltage cable through the current sensor. 4. Install the contactor terminal nut (1). Tighten to 3.4 Nm (30 in. lbs.) 5. Install the two current sensor mounting bolts. Tighten to 6 Nm (51 in. lbs.) 6. Install the four side shield bolts. Tighten to 6 Nm (51 in. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Battery Current Sensor, Hybrid Drive > Component Information > Service and Repair > High Voltage Current Sensor - Removal > Page 999 7. Install the high voltage battery cover See: Hybrid Drive Systems/Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Installation. 8. Perform the high voltage power up procedure . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Battery Temperature Sensor/Switch, Hybrid Drive > Component Information > Service and Repair > High Voltage Thermistor Harness - Removal Battery Temperature Sensor/Switch: Service and Repair High Voltage Thermistor Harness Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Remove the battery cover See: Hybrid Drive Systems/Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Removal. 2. Remove the battery pack fan. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Battery Cooling Fan/Service and Repair/High Voltage Battery Cooling Fan - Removal. 3. Mark the location of each thermistor. 4. Remove the push pins from the air intake thermistor. 5. Disconnect the current sensor (3) See: Battery Current Sensor/Service and Repair/High Voltage Current Sensor - Removal. 6. Disconnect the thermistor harness (1) from the Battery Pack Control Module (BPCM) (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Battery Temperature Sensor/Switch, Hybrid Drive > Component Information > Service and Repair > High Voltage Thermistor Harness - Removal > Page 1004 7. Remove the thermistor harness (1) from the battery pack (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Battery Temperature Sensor/Switch, Hybrid Drive > Component Information > Service and Repair > High Voltage Thermistor Harness - Removal > Page 1005 Battery Temperature Sensor/Switch: Service and Repair High Voltage Thermistor Harness Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Install the thermistor harness (1) into the marked locations. 2. Install the push pins for the air intake thermistor (1). 3. Install the battery pack fan See: Hybrid Drive Systems/Battery System, Hybrid Drive/Battery Cooling Fan/Service and Repair/High Voltage Battery Cooling Fan - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Battery Temperature Sensor/Switch, Hybrid Drive > Component Information > Service and Repair > High Voltage Thermistor Harness - Removal > Page 1006 4. Connect the current sensor (3) See: Battery Current Sensor/Service and Repair/High Voltage Current Sensor - Installation. 5. Connect the thermistor harness (1) to the Battery Pack Control Module (BPCM) (2). 6. Install the high voltage battery cover See: Hybrid Drive Systems/Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Installation. 7. Perform the High Voltage Power Up procedure . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Hybrid Battery Service Switch > Component Information > Service and Repair > High Voltage Service Disconnect - Removal Hybrid Battery Service Switch: Service and Repair High Voltage Service Disconnect - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Remove the drivers side high voltage battery access panel. 2. Service disconnect (1) as it is active in the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Hybrid Battery Service Switch > Component Information > Service and Repair > High Voltage Service Disconnect - Removal > Page 1011 3. Pull up on the service disconnect handle. 4. Pull the handle down towards front of the vehicle. 5. Remove the service disconnect from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Hybrid Battery Service Switch > Component Information > Service and Repair > High Voltage Service Disconnect - Removal > Page 1012 Hybrid Battery Service Switch: Service and Repair High Voltage Service Disconnect - Installation INSTALLATION 1. Install the service disconnect into the vehicle. 2. Pull the handle up towards the roof of the vehicle. 3. Push down on the service disconnect handle. 4. Install the driver side high voltage battery cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Hybrid Drive Coolant Temperature Sensor > Component Information > Diagrams Hybrid Drive Coolant Temperature Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 2 WAY SENSOR-TPIM COOLANT TEMPERATURE (HEV) - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Hybrid Drive Coolant Temperature Sensor > Component Information > Diagrams > Page 1016 Hybrid Drive Coolant Temperature Sensor: Description and Operation TPIM COOLING SYSTEM TEMPERATURE SENSOR The TPIM cooling system temperature sensor (2) is used to sense the coolant temperature. The sensor (2) is located in the combination Transmission/TPIM cooler. The coolant sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. As the coolant temperature increases, resistance (voltage) in the sensor decreases. As the temperature decreases, resistance (voltage) in the sensor increases. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Hybrid Drive Coolant Temperature Sensor > Component Information > Service and Repair > TPIM Cooling System Temperature Sensor Removal Hybrid Drive Coolant Temperature Sensor: Service and Repair TPIM Cooling System Temperature Sensor - Removal TPIM COOLING SYSTEM TEMPERATURE SENSOR WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform HEV specific high voltage power down and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the negative battery cable. CAUTION: Disconnecting the 12 V battery from the vehicle within two minutes of the last ignition key transition from Off to Run may cause a Battery Pack Control Module (BPCM) State Of Charge (SOC) mismatch. 3. Raise and support the vehicle. 4. Drain the TPIM cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/TPIM Cooling System Draining NOTE: DO NOT spill coolant on electrical connections or connectors. 5. Disconnect the temperature sensor electrical connector. 6. Remove the temperature sensor (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Hybrid Drive > Hybrid Drive Coolant Temperature Sensor > Component Information > Service and Repair > TPIM Cooling System Temperature Sensor Removal > Page 1019 Hybrid Drive Coolant Temperature Sensor: Service and Repair TPIM Cooling System Temperature Sensor - Installation TPIM COOLING SYSTEM TEMPERATURE SENSOR WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Install the temperature sensor (2) into the Transmission/TPIM cooler (1). 2. Tighten the sensor to 20 Nm (15 ft. lbs.). 3. Connect negative battery cable. 4. Perform HEV specific high voltage power up and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 5. Fill the TPIM cooling system and check for leaks. See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/TPIM Cooling System Filling Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation > Door Ajar Switch - Description Door Switch: Description and Operation Door Ajar Switch - Description DOOR This vehicle has four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Latch/Service and Repair/Front Door Latch - Removal or See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Rear Door Latch - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation > Door Ajar Switch - Description > Page 1025 Door Switch: Description and Operation Door Ajar Switch - Operation DOOR The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The rear door ajar switches are hard wired in series between a body ground and the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). On vehicles not equipped with the optional memory system, the front door ajar switches are also hard wired in series between ground and the EMIC. On vehicles equipped with the optional memory system each front door ajar switch is hard wired in series between ground and its respective driver or passenger Memory Mirror Module (MMM) located in the front door. The MMM then sends electronic door ajar switch status messages to the EMIC over the Controller Area Network (CAN) data bus. Both the EMIC and the MMM read the hard wired door ajar switch inputs through internal pull-ups, then use these inputs to control many electronic functions and features of the vehicle. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 1029 Fuel Gauge Sender: Diagrams Connector - (CHASSIS) 4 WAY MODULE-FUEL PUMP - (CHASSIS) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 1030 Fuel Gauge Sender: Description and Operation DESCRIPTION The fuel pump module assembly (4) is located on the top of the fuel tank (2). The module assembly (5) contains the following components: - An internal fuel filter - A separate fuel pick-up, or inlet filter (3) - A fuel pressure regulator (4) - An electric fuel pump (2) - A lock ring to retain pump module to tank - A soft gasket between tank flange and module - A fuel gauge sending unit (fuel level sensor) (1) - Fuel line connection (6) If the fuel gauge sending unit, electrical fuel pump, primary inlet filter, fuel filter or fuel pressure regulator require service, the fuel pump module must be replaced. Electric Fuel Pump The electric fuel pump is located inside of the fuel pump module. A 12 volt, permanent magnet, electric motor powers the fuel pump. The electric fuel pump is not a separate, serviceable component. Fuel Filters Two fuel filters are used. One is located at the bottom of the fuel pump module. The other is located inside the module. A separate frame mounted fuel filter is not used with any engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 1031 Both fuel filters are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator The fuel pressure regulator is located within fuel pump module. Fuel Gauge Sending Unit (Fuel level sensor) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Gauge Sender: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: The fuel system is under a constant pressure, even with the engine off. Before servicing the fuel pump module, the fuel system pressure must be released. 1. Perform the fuel system pressure release procedure See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Disconnect and isolate the negative battery cable. 3. Drain and remove the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal 4. Note the rotational position of the module before attempting removal. An indexing arrow is located on top of the module for this purpose. 5. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 6. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 7. Rotate the breaker bar counterclockwise to remove the lock ring. 8. Remove the lock ring. The module will spring up slightly when the lock ring is removed. 9. Remove the module from the fuel tank. Be careful not to bend the float arm during removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1034 Fuel Gauge Sender: Service and Repair Fuel Pump Module - Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position the fuel pump module into the opening of the fuel tank. 2. Rotate the module until the embossed alignment arrow points to the center alignment mark. This step must be performed to prevent the float from contacting the side of the fuel tank. Also be sure the fuel fitting on top of the pump module is pointed to the left side of the vehicle. 3. Position the lock ring (5) over the top of the fuel pump module. 4. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 5. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 6. Tighten the lock ring (clockwise) until all seven notches have engaged. 7. Install the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation 8. Lower the vehicle. 9. Connect the fuel line quick connect fitting to the fuel rail (1)See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair 10. Connect the negative battery cable. 11. Install the fuel fill cap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor - Description Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Description DESCRIPTION The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams refer to Wiring. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor - Description > Page 1039 Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the A/C-heater control. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the A/C-heater control. Based upon the resistance in the sensor, the A/C-heater control senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Page 1040 Outside Temperature Display Sensor: Testing and Inspection AMBIENT TEMPERATURE SENSOR The temperature function is supported by the ambient temperature sensor, a wiring circuit, the Controller Area Network (CAN) data bus circuit and the Integrated Power Module (IPM). When the sensor is exposed to temperatures above 55° C (131° F), or if the sensor circuit is shorted, 60° C (130/140° F) will appear in the Electronic Vehicle Information Center (EVIC) display in place of the temperature. When the sensor is exposed to temperatures below -40° C (-40° F) or if the sensor circuit is open, - - ° C (- - ° F) will be displayed on the EVIC. The ambient temperature sensor and circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, further testing of the CAN data bus, IPM and base EVIC system is necessary. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilo ohms. At 55° C (130° F), the sensor resistance is 2.488 kilo ohms. The sensor resistance should read between these two values. If OK, perform further diagnosis of the Electronic Vehicle Information Center (EVIC) system, See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Testing and Inspection. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Turn the ignition switch to the Off position. Disconnect the wire harness connector from the ambient temperature sensor. NOTE: Temperature readings do not update immediately. Allow up to 60 seconds after the ignition switch is turned to the On position for readings to meet test specifications. 2. Turn the ignition switch to the On position. The EVIC display should now read - - ° C (- - ° F). If OK, go to 3. If not OK, repair the shorted sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 3. Turn the ignition switch to the Off position. Taking care not to damage the wire terminals, connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. Turn the ignition switch to the On position. The EVIC display should now read 60 ° C (130/140° F). If OK, go to 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. NOTE: If the EVIC display does not show the ambient temperature in step 4, the vehicle may need to be driven several miles at a speed greater than 32 km/h (20 mph) for the temperature to update. 4. Turn the ignition switch to the Off position. Remove the jumper wire. Turn the ignition switch to the On position and wait until the EVIC display again reads - - ° C (- - ° F). Turn the ignition switch to the Off position. Reconnect the ambient temperature sensor. Turn the ignition switch to the On position. The EVIC display should now read the ambient temperature. If OK, the problem is intermittent. Perform further diagnosis while manipulating the related wire harnesses and components. If not OK, go to 5 5. Clear any Diagnostic Trouble Codes that may have been set while performing the test. Perform further diagnosis of the CAN data bus circuit, the IPM and the ambient temperature sensor (refer to the SENSOR TEST). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor - Removal Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Locate the ambient temperature sensor (1), on the right side of the radiator yoke (2) behind the grille. 3. Disconnect the wire harness connector (3) from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the radiator yoke. 5. Remove the ambient temperature sensor from the radiator yoke. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor - Removal > Page 1043 Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor Installation INSTALLATION 1. Position the ambient temperature sensor (1) onto the radiator yoke (2). 2. Install the screw that secures the ambient temperature sensor to the radiator yoke. Tighten the screw to 5.6 Nm (50 in. lbs.). 3. Connect the wire harness connector (3) to the ambient temperature sensor (1). 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 1047 Parking Brake Warning Switch: Diagrams Connector - (BODY) 1 WAY SWITCH-PARKING BRAKE - (BODY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description > Page 1050 Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Page 1051 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. See: Brakes and Traction Control/Testing and Inspection . If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 1054 Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation Backup Lamp Switch: Description and Operation DESCRIPTION Vehicles with an electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The TRS is described in further detail elsewhere in this service information. Refer to the service and diagnostic information for the automatic transmission type installed in the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1062 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 1063 Brake Light Switch: Diagrams Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-STOP LAMP - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description Brake Light Switch: Description and Operation Stop Lamp Switch - Description DESCRIPTION The brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured to the steering column support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the instrument panel wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. An installed brake lamp switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or removed from its mounting position for any reason, it must be replaced with a new unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description > Page 1066 Brake Light Switch: Description and Operation Stop Lamp Switch - Operation OPERATION The brake lamp switch controls three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the brake lamps and the Controller Antilock Brake (CAB) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a brake lamp switch sense circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Powertrain Control Module on a speed control supply circuit, and supplies this battery voltage to the speed control servo solenoids (dump, vacuum, and vent) on a speed control brake switch output circuit only when the speed control system is turned ON and the brake pedal is released (brake lamp switch plunger is depressed). The components of the self-adjusting brake switch plunger consist of a two-piece telescoping plunger, a split plunger locking collar, and a release wedge. The release lever has a shaft with a wedge that spreads the plunger locking collar to an open or released position. After the switch is installed and the brake pedal is released, the plunger telescopes to the correct adjustment position. When the release lever is moved to the release position, the wedge is disengaged from the locking collar causing the collar to apply a clamping pressure to the two plunger halves, fixing the plunger length. The brake lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 1067 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. CAUTION: Do not remove the brake lamp switch from the mounting bracket. The self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the ineffective brake lamp switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal Brake Light Switch: Service and Repair Stop Lamp Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Locate the brake lamp switch (1) near the support bracket on the lower steering column (3). 3. Disconnect the wire harness connector (5) from the brake lamp switch. 4. Rotate the brake lamp switch housing clockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the switch mounting bracket (4). 5. Pull the switch straight back from the keyed hole to remove it from the bracket. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 6. Discard the removed brake lamp switch . Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal > Page 1070 Brake Light Switch: Service and Repair Stop Lamp Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. CAUTION: The brake lamp switch plunger MUST be in the fully extended position prior to releasing the brake pedal or setting the plunger length to ensure proper switch adjustment and operation. Do not manually press the plunger into the switch body prior to or during switch installation, and do not pull the brake pedal upward prior to setting the plunger length using the plunger adjustment release lever as described in the following procedure. 1. Depress and hold the brake pedal in the depressed position. 2. Align the tabs on the brake lamp switch locking collar with the keyed hole in the switch mounting bracket (4) on the lower steering column (3). 3. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the switch mounting bracket until the switch housing (1) is firmly seated against the bracket. 4. Rotate the switch housing counterclockwise about 30 degrees to engage the tabs on the locking collar with the switch mounting bracket. CAUTION: Release, but do not pull up on the brake pedal before the switch plunger adjustment has been completed. 5. Release the brake pedal, but do not pull it upward. CAUTION: Be certain that the brake lamp switch plunger is in contact with the flag bracket on the brake pedal arm prior to rotating the plunger adjustment release lever. If the plunger is not contacting the flag bracket, depress and hold the brake pedal while manually pulling the plunger out from the switch body to the fully extended position. Then release the brake pedal, but do not pull it upward. 6. Rotate the plunger adjustment release lever (2) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch must be installed. 7. Reconnect the wire harness connector (5) to the brake lamp switch. 8. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 1074 Combination Switch: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Multifunction Switch - Description Combination Switch: Description and Operation Multifunction Switch - Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Front Washer Control - The multi-function switch control knob provides a momentary front WASH position for front washer system operation. - Front Wiper Control - The multi-function switch control knob provides two continuous front wipe switch positions, LOW speed or HIGH speed; and an intermittent front wipe mode with five delay interval positions. Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Multifunction Switch - Description > Page 1077 Combination Switch: Description and Operation Multifunction Switch - Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control front washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control front wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Front Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the front WASH mode. The washer pump will continue to operate in the front washer mode until the control knob is released or for 10 continuous seconds, whichever occurs first. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front washer switch status messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The FCM responds by energizing or de-energizing the washer pump in the front washer mode. - Front Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous front wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front wiper switch status messages to the FCM over the CAN data bus. The FCM responds by energizing or de-energizing the wiper on/off and high/low relays in the Power Distribution Center (PDC) for front wiper system control. - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the FCM over the CAN data bus. The FCM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the FCM over the CAN data bus. The FCM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the FCM over the CAN data bus. The FCM energizes and flashes or de-energizes the selected left or right turn signal circuits. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Page 1078 Combination Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the multi-function switch from the switch mounting housing on the steering column. See: Service and Repair/Multifunction Switch Removal. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Multifunction Switch - Removal Combination Switch: Service and Repair Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 1081 8. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 9. Rotate the steering wheel far enough to access and remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 10. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 1082 Combination Switch: Service and Repair Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Rotate the steering wheel far enough to install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. Be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 1083 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation > Door Ajar Switch - Description Door Switch: Description and Operation Door Ajar Switch - Description DOOR This vehicle has four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Latch/Service and Repair/Front Door Latch - Removal or See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Rear Door Latch - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation > Door Ajar Switch - Description > Page 1088 Door Switch: Description and Operation Door Ajar Switch - Operation DOOR The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The rear door ajar switches are hard wired in series between a body ground and the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). On vehicles not equipped with the optional memory system, the front door ajar switches are also hard wired in series between ground and the EMIC. On vehicles equipped with the optional memory system each front door ajar switch is hard wired in series between ground and its respective driver or passenger Memory Mirror Module (MMM) located in the front door. The MMM then sends electronic door ajar switch status messages to the EMIC over the Controller Area Network (CAN) data bus. Both the EMIC and the MMM read the hard wired door ajar switch inputs through internal pull-ups, then use these inputs to control many electronic functions and features of the vehicle. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 1092 Hazard Warning Switch: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 1096 Headlamp Dimmer Switch: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Multifunction Switch - Description Headlamp Dimmer Switch: Description and Operation Multifunction Switch - Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Front Washer Control - The multi-function switch control knob provides a momentary front WASH position for front washer system operation. - Front Wiper Control - The multi-function switch control knob provides two continuous front wipe switch positions, LOW speed or HIGH speed; and an intermittent front wipe mode with five delay interval positions. Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Multifunction Switch - Description > Page 1099 Headlamp Dimmer Switch: Description and Operation Multifunction Switch - Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control front washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control front wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Front Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the front WASH mode. The washer pump will continue to operate in the front washer mode until the control knob is released or for 10 continuous seconds, whichever occurs first. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front washer switch status messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The FCM responds by energizing or de-energizing the washer pump in the front washer mode. - Front Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous front wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front wiper switch status messages to the FCM over the CAN data bus. The FCM responds by energizing or de-energizing the wiper on/off and high/low relays in the Power Distribution Center (PDC) for front wiper system control. - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the FCM over the CAN data bus. The FCM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the FCM over the CAN data bus. The FCM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the FCM over the CAN data bus. The FCM energizes and flashes or de-energizes the selected left or right turn signal circuits. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Page 1100 Headlamp Dimmer Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the multi-function switch from the switch mounting housing on the steering column. See: Combination Switch/Service and Repair/Multifunction Switch - Removal. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Multifunction Switch - Removal Headlamp Dimmer Switch: Service and Repair Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 1103 8. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 9. Rotate the steering wheel far enough to access and remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 10. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 1104 Headlamp Dimmer Switch: Service and Repair Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Rotate the steering wheel far enough to install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. Be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 1105 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 1109 Headlamp Switch: Diagrams Connector - (INSTRUMENT PANEL) 10 WAY SWITCH-HEADLAMP - (INSTRUMENT PANEL) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch - Description Headlamp Switch: Description and Operation Headlamp Switch - Description DESCRIPTION The headlamp switch (1) is located on the instrument panel, to the left of the steering column. Three different switches are used. The standard switch features a three-position rotary knob (4) for exterior lighting control and a thumbwheel (2) for panel lamps dimming and interior lighting control. An optional switch has a momentary push button (3) added for front fog lamp control. A second optional switch has the same thumbwheel and momentary push button, but has a fourth position added to the rotary knob for selecting the optional automatic headlamps feature. Each of these switches is constructed of molded plastic. The rotary knob is molded plastic and knurled around its circumference to ease operator control. The thumbwheel is also plastic and knurled. The optional front fog lamp push button is plastic with a smooth finish and an International Control and Display Symbol icon for Front Fog Light applied to it. The switch face plate is also labeled with graphics and icons to clearly identify the many functions of the rotary knob and thumbwheel. Three screws secure the switch to the back of the cluster bezel through integral mounting flanges that are molded to each side of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A panel dimmer controlled incandescent bulb soldered to the circuit board within the switch provides back lighting for visibility at night, but is not serviceable. The headlamp switch cannot be repaired and, if ineffective or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch - Description > Page 1112 Headlamp Switch: Description and Operation Headlamp Switch - Operation OPERATION The headlamp switch uses two resistor multiplexed outputs to control the many functions and features it provides. The switch receives a clean ground from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a headlamp switch return circuit. It then provides outputs to the EMIC on a headlamp switch signal circuit to control exterior lighting functions, and on a panel lamps dimmer signal circuit to control panel dimmer and interior lighting functions. The switch illumination circuit receives a path to ground at all times through the left instrument panel ground circuit. The illumination level is controlled by a Pulse-Width Modulated (PWM) output received from the EMIC on a headlamp switch illumination control circuit. The EMIC controls this output based upon the dimmer signal select mux input from the headlamp switch. The headlamp switch operates as follows: - Front Fog Lamps Control - For vehicles so equipped, the fog lamp push button on the headlamp switch is depressed to activate or deactivate the optional front fog lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic fog lamp switch status messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The FCM responds by energizing or de-energizing the front fog lamp relay in the Power Distribution Center (PDC) and by sending an electronic message back to the EMIC to control the front fog lamp indicator. - Exterior Lighting Control - The rotary knob on the headlamp switch is rotated to a detent position to activate or deactivate the exterior lighting. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic exterior lighting switch status messages to the FCM over the CAN data bus. The FCM responds by energizing or de-energizing the park lamp relay in the PDC and the high or low beam headlamp circuits, and by sending an electronic message back to the EMIC to control the high beam indicator. The FCM also remembers which headlamp beams were last selected using the multi-function switch, and energizes those beams by default the next time the headlamps are turned ON. If the vehicle is equipped with optional automatic headlamps and the A (Automatic) position is selected, the EMIC also monitors an input from a sun load sensor on the instrument panel and, based upon the monitored ambient light levels, responds by automatically sending appropriate messages to the FCM to turn the exterior lighting ON or OFF while the ignition switch is in the ON position. - Interior Lighting Control - The thumbwheel on the headlamp switch is rotated to the dome DEFEAT, dome ON, PARADE mode, or one of the six panel dimmer detent positions to control the interior courtesy/dome and panel lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate interior lighting control outputs through its internal courtesy lamp driver circuits, electronic dimming level messages to other modules over the CAN data bus, and the proper PWM outputs to control dimming levels through several panel dimmer illumination control driver circuits. The headlamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 1113 Headlamp Switch: Testing and Inspection HEADLAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the cluster bezel and the headlamp switch from the instrument panel as a unit. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Cluster Bezel - Removal. 2. Disconnect the wire harness connector from the back of the headlamp switch. 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective headlamp switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch - Removal Headlamp Switch: Service and Repair Headlamp Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the cluster bezel (1) from the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Cluster Bezel - Removal. 3. Disconnect the wire harness connector from the back of the headlamp switch (2). 4. Place the cluster bezel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the bezel from cosmetic damage. 5. Remove the three screws (3) that secure the headlamp switch to the back of the cluster bezel. 6. Remove the headlamp switch from the cluster bezel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch - Removal > Page 1116 Headlamp Switch: Service and Repair Headlamp Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the headlamp switch (2) to the back of the cluster bezel (1). 2. Install and tighten the three screws (3) that secure the headlamp switch to the cluster bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Position the cluster bezel close enough to the instrument panel to reconnect the wire harness connector to the back of the headlamp switch. 4. Reinstall the cluster bezel onto the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Cluster Bezel - Installation. 5. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 1120 Horn Switch: Diagrams Connector - (STEERING WHEEL) 2 WAY SWITCH-HORN - (STEERING WHEEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 1121 Horn Switch: Testing and Inspection HORN SWITCH The most reliable, efficient and accurate means to diagnose the horn system requires the use of a scan tool and the proper diagnostic procedure information. For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1127 Accelerator Pedal Position Sensor: Diagrams Connector - (HEADLAMP AND DASH) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (HEADLAMP AND DASH) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (6) is attached to the accelerator pedal assembly (4) under the instrument panel. The APPS is used only with the 5.7L V-8 engine. The APPS is part of the pedal assembly and is a non-serviceable part and the pedal assembly has to be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 1130 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) is a linear potentiometer. It provides the Powertrain Control Module (PCM) with a DC voltage signal proportional to the angle, or position of the accelerator pedal. The APPS signal is translated (along with other sensors) to place the throttle plate (within the throttle body) to a pre-determined position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor > Page 1135 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1136 Camshaft Position Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-CAMSHAFT POSITION - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description 5.7L The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 1139 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation 5.7L The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.7L The Camshaft Position Sensor (CMP) (3) is located on right side of timing gear/chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from timing gear/chain cover. 4. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 1142 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in timing gear/chain cover. 2. Install sensor (2) into timing gear/chain cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing gear/chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 Nm (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1146 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1147 Coolant Temperature Sensor/Switch (For Computer): Diagrams Connector - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1151 Crankshaft Position Sensor: Diagrams Connector (5.7L) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (5.7L) - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description 5.7L The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 1154 Crankshaft Position Sensor: Description and Operation Operation 5.7L Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On the 5.7L V-8 engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 5.7L 1. Raise vehicle. 2. Disconnect CKP electrical connector (2) at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 1157 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking and twisting action. CAUTION: Before tightening the CKP sensor mounting bolt, be sure the sensor is completely flush to the cylinder block. If the CKP sensor is not flush, damage to the sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1161 Fuel Level Sensor: Diagrams Connector - (CHASSIS) 4 WAY MODULE-FUEL PUMP - (CHASSIS) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Level Sensor: Description and Operation Fuel Pump Module - Description DESCRIPTION The fuel pump module assembly (4) is located on the top of the fuel tank (2). The module assembly (5) contains the following components: - An internal fuel filter - A separate fuel pick-up, or inlet filter (3) - A fuel pressure regulator (4) - An electric fuel pump (2) - A lock ring to retain pump module to tank - A soft gasket between tank flange and module - A fuel gauge sending unit (fuel level sensor) (1) - Fuel line connection (6) If the fuel gauge sending unit, electrical fuel pump, primary inlet filter, fuel filter or fuel pressure regulator require service, the fuel pump module must be replaced. Electric Fuel Pump The electric fuel pump is located inside of the fuel pump module. A 12 volt, permanent magnet, electric motor powers the fuel pump. The electric fuel pump is not a separate, serviceable component. Fuel Filters Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 1164 Two fuel filters are used. One is located at the bottom of the fuel pump module. The other is located inside the module. A separate frame mounted fuel filter is not used with any engine. Both fuel filters are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator The fuel pressure regulator is located within fuel pump module. Fuel Gauge Sending Unit (Fuel level sensor) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 1165 Fuel Level Sensor: Description and Operation Variable Speed Fuel Pump Module (HEV) Description DESCRIPTION - HEV The variable speed fuel pump module (5) is located on the top of the fuel tank and contains the following: - Internal fuel filter - Separate fuel pick-up, or inlet filter (3) - Fuel pressure regulator (4) - Variable speed fuel pump (2) - Lock ring to retain the pump module to the tank - O-ring gasket between the tank flange and pump module - Fuel gauge sending unit (fuel level sensor) (1) - Fuel line connection (6) If the fuel gauge sending unit (fuel level sensor), variable speed fuel pump, primary inlet filter, fuel filter or fuel pressure regulator require service, the variable speed fuel pump module must be replaced as a unit. Variable Speed Fuel Pump The Hybrid Electric Vehicle (HEV) uses a variable speed fuel pump module, an additional fuel pump speed relay and a resistor to provide low speed capability to the fuel pump system. A diagnostic monitor circuit allows the PCM to verify operation of the following two circuits: - Fuel pump relay control circuit which results in closing the fuel pump relay allowing current to flow through the fuel pump speed relay for high speed fuel pump operation. - Fuel pump speed relay control circuit which results in closing the fuel pump relay and fuel pump speed relay allowing current to flow through the resistor for low speed fuel pump operation. The variable speed fuel pump is not a separate, serviceable component. Fuel Filters Two fuel filters are used. One is located at the bottom of the fuel pump module. The other is located inside the module. A separate frame mounted fuel filter is not used. Both fuel filters are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator The fuel pressure regulator is located within the fuel pump module and is not a separate, serviceable component. Fuel Gauge Sending Unit (fuel level sensor) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, a float arm, and a variable resistor track (card). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Level Sensor: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: The fuel system is under a constant pressure, even with the engine off. Before servicing the fuel pump module, the fuel system pressure must be released. 1. Perform the fuel system pressure release procedure See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Disconnect and isolate the negative battery cable. 3. Drain and remove the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal 4. Note the rotational position of the module before attempting removal. An indexing arrow is located on top of the module for this purpose. 5. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 6. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 7. Rotate the breaker bar counterclockwise to remove the lock ring. 8. Remove the lock ring. The module will spring up slightly when the lock ring is removed. 9. Remove the module from the fuel tank. Be careful not to bend the float arm during removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1168 Fuel Level Sensor: Service and Repair Fuel Pump Module - Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position the fuel pump module into the opening of the fuel tank. 2. Rotate the module until the embossed alignment arrow points to the center alignment mark. This step must be performed to prevent the float from contacting the side of the fuel tank. Also be sure the fuel fitting on top of the pump module is pointed to the left side of the vehicle. 3. Position the lock ring (5) over the top of the fuel pump module. 4. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 5. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 6. Tighten the lock ring (clockwise) until all seven notches have engaged. 7. Install the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation 8. Lower the vehicle. 9. Connect the fuel line quick connect fitting to the fuel rail (1)See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair 10. Connect the negative battery cable. 11. Install the fuel fill cap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1169 Fuel Level Sensor: Service and Repair Variable Speed Fuel Pump Module (HEV) - Removal REMOVAL - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: The fuel system is under a constant pressure, even with the engine off. Before servicing the fuel pump module, the fuel system pressure must be released. 1. Perform the fuel system pressure release procedure See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 3. Disconnect the 12 volt battery system ground isolation connector (1). 4. Drain the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Procedures for Draining Fuel Tank - HEV procedure. 5. Remove the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal NOTE: Prior to removing the variable speed fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. CAUTION: An indexing arrow is located on top of the variable speed fuel pump module to clock it's position into the fuel tank, note it's location for reassembly. 6. Position the lock ring remover/installer 9340 (1) into the notches on the outside edge of the lock ring (2). 7. Install a 1/2 inch drive breaker bar (4) into the lock ring remover/installer 9340 (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1170 NOTE: The variable speed fuel pump module will spring up slightly when the lock ring is removed. 8. Rotate the breaker bar counterclockwise and remove the lock ring. CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 9. Remove the variable speed fuel pump module (3) from the fuel tank. Be careful not to bend the float arm during removal. 10. Remove and discard the rubber O-ring seal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1171 Fuel Level Sensor: Service and Repair Variable Speed Fuel Pump Module (HEV) - Installation INSTALLATION - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Using a new rubber O-ring seal, position the variable speed fuel pump module into the opening of the fuel tank. 2. Rotate the variable speed fuel pump module until the embossed alignment arrow points to the center alignment mark as noted during disassembly. This step must be performed to prevent the float from contacting the side of the fuel tank. 3. Position the lock ring (2) over the top of the variable speed fuel pump module (3). 4. Position the lock ring remover/installer 9340 (1) into the notches on the outside edge of the lock ring (2). 5. Install a 1/2 inch drive breaker bar (4) into the lock ring remover/installer 9340 (1). 6. Tighten the lock ring (clockwise) until all seven notches have engaged. 7. Install the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation 8. Lower the vehicle. 9. Install the fuel fill cap. 10. Connect the fuel line quick connect fitting to the fuel rail (1)See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 1172 11. Connect the 12 volt battery system ground isolation connector (1). 12. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 13. Start the engine and check for leaks at all fuel tank connections. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Pressure Sensor: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set Fuel Tank Pressure Sensor: Customer Interest Fuel System - MIL ON/DTC P1446 Set NUMBER: 08-005-10 GROUP: Electrical DATE: April 01, 2010 SUBJECT: Fuel Tank Pressure Sensor Connector OVERVIEW: This Bulletin involves replacing the fuel tank pressure sensor connector for diagnostic Trouble Code (DTC) P1446 - Fuel Tank Control System Performance - HEV. MODELS: 2009 (HB) Durango 2009 (HG) Aspen SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that DTC P1446 - Fuel Tank Control System Performance - HEV has been set. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN) verify if P1446 - Fuel Tank Control System Performance - HEV is active. If DTC P1446 - Fuel Tank Control System Performance - HEV is active proceed with repair. Check the service history of the vehicle. If the DTC has ever been reported in the past then proceed with the repair. If DTC's are present other then the one listed above record them on the repair order and with the appropriate Diagnostic Procedures available in TechCONNECT repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: 1. Lower the fuel tank as per the directions on tech connect Emissions Control > Evaporative Emissions > Sensor, Fuel Pressure HEV > Removal HEV. 2. Remove convoluted tubing from the wiring harness. 3. Cut the wires going to the sensor connector 2 inches from the connector. 4. Using the standard crimp/solder/heat shrink procedure for wire splicing found in DealerCONNECT > TechCONNECT > Wiring > Wiring Diagram Information > Wire, add new harness extension to vehicle harness. 5. Check the Pressure Sensor for corrosion on the sensor it self, is it corroded? a. No >>> proceed to Step # 6. b. Yes >>> replace the sensor and continue with repairs. 6. Reinstall connector on to the sensor. 7. Wrap convolute with electrical tape. 8. Reinstall Fuel tank into the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Pressure Sensor: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set > Page 1181 9. Perform StarSCAN diagnostics, clear any stored codes. Re-key to confirm P1446 fault is not active. 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set Fuel Tank Pressure Sensor: All Technical Service Bulletins Fuel System - MIL ON/DTC P1446 Set NUMBER: 08-005-10 GROUP: Electrical DATE: April 01, 2010 SUBJECT: Fuel Tank Pressure Sensor Connector OVERVIEW: This Bulletin involves replacing the fuel tank pressure sensor connector for diagnostic Trouble Code (DTC) P1446 - Fuel Tank Control System Performance - HEV. MODELS: 2009 (HB) Durango 2009 (HG) Aspen SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that DTC P1446 - Fuel Tank Control System Performance - HEV has been set. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN) verify if P1446 - Fuel Tank Control System Performance - HEV is active. If DTC P1446 - Fuel Tank Control System Performance - HEV is active proceed with repair. Check the service history of the vehicle. If the DTC has ever been reported in the past then proceed with the repair. If DTC's are present other then the one listed above record them on the repair order and with the appropriate Diagnostic Procedures available in TechCONNECT repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: 1. Lower the fuel tank as per the directions on tech connect Emissions Control > Evaporative Emissions > Sensor, Fuel Pressure HEV > Removal HEV. 2. Remove convoluted tubing from the wiring harness. 3. Cut the wires going to the sensor connector 2 inches from the connector. 4. Using the standard crimp/solder/heat shrink procedure for wire splicing found in DealerCONNECT > TechCONNECT > Wiring > Wiring Diagram Information > Wire, add new harness extension to vehicle harness. 5. Check the Pressure Sensor for corrosion on the sensor it self, is it corroded? a. No >>> proceed to Step # 6. b. Yes >>> replace the sensor and continue with repairs. 6. Reinstall connector on to the sensor. 7. Wrap convolute with electrical tape. 8. Reinstall Fuel tank into the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set > Page 1187 9. Perform StarSCAN diagnostics, clear any stored codes. Re-key to confirm P1446 fault is not active. 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 1191 Intake Air Temperature Sensor: Diagrams Connector HEV - (ENGINE) 2 WAY SENSOR-INTAKE AIR TEMPERATURE HEV - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor - Description Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Description DESCRIPTION The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor - Description > Page 1194 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Operation OPERATION The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal 5.7L The intake manifold air temperature (IAT) sensor is installed into the front of the intake manifold air box plenum (1). 1. Disconnect electrical connector (2) from IAT sensor. 2. Clean dirt from intake manifold at sensor base. 3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counterclockwise for removal. 4. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 1197 Intake Air Temperature Sensor: Service and Repair Installation 5.7L 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold (1). 3. Position sensor (2) into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) Knock Sensor: Locations Knock Sensor 1 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 1202 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 1203 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 1204 Knock Sensor: Locations Knock Sensor 2 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 1205 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way Knock Sensor: Diagrams Knock Sensor 2 (3.7L/5.7L) 2 Way Connector (3.7L/5.7L) - (ENGINE) 2 WAY SENSOR-KNOCK 2 (3.7L/5.7L) - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way > Page 1208 Knock Sensor: Diagrams Knock Sensor 1 (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-KNOCK 1 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor - Description Knock Sensor: Description and Operation Knock Sensor - Description DESCRIPTION 3.7L - Two knock sensors (1) are bolted to the cylinder block under the intake manifold. 4.7L - One knock sensor (1) is bolted to the cylinder block under the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor - Description > Page 1211 5.7L - Two knock sensors (1) are bolted to each side of the cylinder block (outside) under each exhaust manifold (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor - Description > Page 1212 Knock Sensor: Description and Operation Knock Sensor - Operation OPERATION When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric crystal which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal 5.7L Two knock sensors (1) are used. Each sensor is bolted to the outside of the cylinder block below the exhaust manifold (3). 1. Raise the vehicle. 2. Disconnect the knock sensor electrical connector (5). 3. Remove the knock sensor mounting bolt (2). NOTE: Note the foam strip on bolt threads. This foam strip is used only to retain the bolts to the sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove the knock sensor (1) from the engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 1215 Knock Sensor: Service and Repair Knock Sensor - Installation 5.7L 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). NOTE: Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt (2). Tighten to 15 +/- 2 ft. lbs. (20 Nm) (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1219 Manifold Pressure/Vacuum Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-MAP - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1220 Manifold Pressure/Vacuum Sensor: Description and Operation OPERATION The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal 5.7L 1. Disconnect Map sensor (1) electrical connector. 2. Rotate MAP sensor (1) 1/4 turn counterclockwise for removal. 3. Lift MAP sensor (1) upward. 4. Check condition of sensor o-ring (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 1223 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 5.7L 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring (2) for cuts or tears. 3. Position MAP sensor (1) into manifold. 4. Rotate MAP sensor (1) clockwise for installation. 5. Connect electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 1227 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 1228 Oil Pressure Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-OIL PRESSURE - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 1229 Oil Pressure Sensor: Description and Operation DESCRIPTION The oil pressure sensor uses the following three circuits: - Signal circuit to the PCM - Sensor ground circuit through the PCM - 5 volt reference circuit from the PCM The oil pressure sensor returns a voltage signal back to the PCM with reference to oil pressure. Ground for the sensor is supplied by the PCM. The oil pressure sensor is located on the right side of the engine block. The sensor screws into the engines main oil gallery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Oil Pressure Sensor - Removal Oil Pressure Sensor: Service and Repair Oil Pressure Sensor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the High Voltage Power Down Procedure . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Raise and support the vehicle. 3. Disconnect the oil pressure sensor electrical connector (1). 4. Remove the oil pressure sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Oil Pressure Sensor - Removal > Page 1232 Oil Pressure Sensor: Service and Repair Oil Pressure Sensor - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions NOTE: Apply Mopar(R) Thread Sealant with PTFE to the sensor threads before installing into the engine block. 1. Install the oil pressure sensor (1). 2. Connect the oil pressure sensor electrical connector (1). 3. Lower the vehicle. 4. Perform the High Voltage Power Up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 1237 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 1238 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 1239 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 1240 Oxygen Sensor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 1241 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 1242 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 1243 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 1244 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 1245 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way Oxygen Sensor: Diagrams Oxygen Sensor 1/1 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/1 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way > Page 1248 Oxygen Sensor: Diagrams Oxygen Sensor 1/2 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/2 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way > Page 1249 Oxygen Sensor: Diagrams Oxygen Sensor 2/1 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/1 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way > Page 1250 Oxygen Sensor: Diagrams Oxygen Sensor 2/2 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/2 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1251 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1252 Oxygen Sensor: Description and Operation DESCRIPTION The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors. Federal Emission Packages : Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1253 Oxygen Sensor: Testing and Inspection CHECKING THE OXYGEN SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. OXYGEN SENSOR, WIRING, OR CONNECTORS NOTE: Diagnose and repair any O2 sensor or rationality DTCs before proceeding with this test. NOTE: When performing this procedure as part of another diagnostic process, it may be necessary to repeat this test for all of the oxygen sensors on the vehicle. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 2 2. OXYGEN SENSOR VOLTAGE 1. Start the engine and allow it to reach normal operating temperature. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 2. With a scan tool, monitor all O2 Sensor voltage readings. Is the voltage switching between 2.5 and 3.4 volts for all O2 sensors? Yes - Go to 3 - Perform the POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 4 3. O2 SENSOR HEATER OPERATION 1. Turn the ignition off. NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0 volts. 2. Turn the ignition on. 3. With a scan tool, actuate the O2 Sensor heater. 4. With the scan tool, monitor O2 Sensor voltage for at least 2 minutes. Does the voltage stay above 4.5 volts? Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1254 Yes - Go to 4 - Perform the POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Test complete. 4. O2 SENSOR 1. Turn the ignition off. NOTE: Check for contaminants that may cause improper O2 Sensor operation, such as contaminated fuel, unapproved silicone, or evidence of oil or coolant. 2. Disconnect the O2 Sensor harness connector. 3. Turn the ignition on. 4. With a scan tool, monitor the O2 Sensor voltage. NOTE: The voltage should be approximately 5.0 volts with the connector disconnected. 5. Connect a jumper wire between the signal circuit and the return circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from 5.0 volts to 2.5 volts with the jumper wire in place. Is the O2 Sensor voltage displayed on the scan tool as described? Yes - Replace the O2 Sensor. - Perform the POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 5 5. O2 SENSOR SIGNAL CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Signal circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor signal circuit for a short to ground, open circuit, short to voltage, or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 6 6. O2 SENSOR RETURN CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Return circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor return circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 1255 No - Go to 7 7. POWERTRAIN CONTROL MODULE (PCM) 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the O2 sensor and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Monitor the scan tool data relative to the components tested in this procedure and wiggle test the wiring and connectors. 5. Look for the data to change or for a DTC to set during the wiggle test. 6. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Replace and program the Powertrain Control Module (PCM). - Perform the POWERTRAIN VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal REMOVAL Refer to graphic for typical O2S (oxygen sensor) locations if equipped with four oxygen sensors. Refer to graphic for typical O2S (oxygen sensor) locations if equipped with two oxygen sensors. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow the engine to cool before removing the oxygen sensor. 1. Raise and support vehicle. 2. 4-Sensor System If removing the right-upstream (2/1) sensor, remove the right-front tire/wheel, and then remove the plastic inner fender liner. 3. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on the wire going into sensor. 4. Remove O2S sensor with an oxygen sensor removal and installation tool. 5. Clean threads in exhaust pipe using appropriate tap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 1258 Oxygen Sensor: Service and Repair Installation INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor and tighten to 30 ft. lbs. (41 Nm) torque. 2. Connect O2S sensor wire connector. 3. 4-Sensor System: If installing the right-upstream (2/1) sensor, install plastic inner fender liner, and right-front tire/wheel. 4. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1262 Transmission Position Switch/Sensor: Diagrams Connector (HEV) - (TRANSMISSION SIDE) 12 WAY SENSOR-TRANSMISSION RANGE (HEV) - (TRANSMISSION SIDE) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Description DESCRIPTION The transmission range sensor (2) is located inside the transmission and connects to the mainshaft (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description > Page 1265 Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Disconnect the transmission range sensor electrical connector (1). 3. Remove the bolt (1) securing the transmission range sensor (2) to the mainshaft (3). 4. Remove the mainshaft roll pin (1) from the transmission case (2) and remove the mainshaft. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1268 5. Lower the transmission range sensor (2) and remove the park actuator rod (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1269 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install the park actuator rod (3) into the transmission range sensor (2). 2. Install the mainshaft roll pin (1) to the transmission case (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1270 3. Position the transmission range sensor (2) into place in the transmission case. 4. Install the mainshaft (3) into the transmission case. 5. Install the transmission range sensor mounting bolt. Tighten the bolt to 8 Nm (71 NOTE: Before install the TEHCM / valve body assembly to the transmission case, be certain the existing gasket is in place. 6. Install the valve body. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 1275 Accelerator Pedal Position Sensor: Diagrams Connector - (HEADLAMP AND DASH) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (HEADLAMP AND DASH) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (6) is attached to the accelerator pedal assembly (4) under the instrument panel. The APPS is used only with the 5.7L V-8 engine. The APPS is part of the pedal assembly and is a non-serviceable part and the pedal assembly has to be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 1278 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) is a linear potentiometer. It provides the Powertrain Control Module (PCM) with a DC voltage signal proportional to the angle, or position of the accelerator pedal. The APPS signal is translated (along with other sensors) to place the throttle plate (within the throttle body) to a pre-determined position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation Fuel Pressure Sensor/Switch: Description and Operation DESCRIPTION - HEV The fuel tank pressure sensor provides the PCM with information on vapor pressure inside the fuel tank. The sensor is a diaphragm-type pressure sensor and varies its voltage output depending on fuel tank pressure. When the fuel tank isolation valve is activated (closed), preventing fuel vapors from leaving the tank, the PCM will monitor the fuel tank pressure sensor to prevent pressure from increasing or decreasing to an unsafe level. Excessive fuel tank pressure could cause fuel vapors to vent out the fuel cap or damage system components while insufficient fuel tank pressure (vacuum) caused by lack of air entering the tank to take the place of consumed fuel could lead to collapsed tank, lines or loss of fuel pressure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor - Removal REMOVAL - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the fuel system pressure release procedure See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 3. Disconnect the 12 volt battery system ground isolation connector (1). 4. Raise and support the vehicle. 5. Disconnect the fuel fill hose (1) at the rear of the fuel tank. 6. Disconnect the fuel fill vapor line quick-connect fitting (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 1284 7. Disconnect the electrical connector at the EVAP System Integrity Monitor (ESIM) switch (2). 8. Disconnect the fuel tank isolation valve electrical connector (2) at the EVAP canister mounting bracket. 9. Disconnect the fuel tank isolation valve vapor line quick-connect fitting (1) to the purge solenoid tubing connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 1285 10. Support the fuel tank with a suitable hydraulic jack. 11. Remove the two fuel tank support strap retaining bolts (2) and position both support straps (3) aside. 12. Carefully lower the fuel tank (1) a few inches. 13. Disconnect the fuel pressure sensor electrical connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 1286 14. Thoroughly clean the area around the fuel pressure sensor. 15. Remove the fuel pressure sensor from the fuel tank (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 1287 Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor - Installation INSTALLATION - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Install the fuel pressure sensor (1) into the fuel tank. 2. Connect the fuel pressure sensor electrical connector (1). 3. Raise the fuel tank until snug to the body. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 1288 4. Position both fuel tank support straps (3), install the retaining bolts (2) and tighten to 40 Nm (30 ft. lbs.). 5. Remove the hydraulic jack. 6. Connect the fuel tank isolation valve vapor line quick-connect fitting (1) to the purge solenoid tubing connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 1289 7. Connect the fuel tank isolation valve electrical connector (2) at the EVAP canister mounting bracket. 8. Connect the electrical connector at the EVAP System Integrity Monitor (ESIM) switch (2). 9. Connect the fuel fill hose (1) at the rear of the fuel tank. 10. Connect the fuel fill vapor line quick-connect fitting (2). 11. Lower the vehicle. 12. Connect the 12 volt battery system ground isolation connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 1290 13. Connect the fuel line quick connect fitting to the fuel rail (1) See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair 14. Install the fuel fill cap. 15. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 16. Start the engine and check for leaks at all fuel tank connections. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor > Page 1296 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1297 Camshaft Position Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-CAMSHAFT POSITION - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description 5.7L The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 1300 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation 5.7L The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.7L The Camshaft Position Sensor (CMP) (3) is located on right side of timing gear/chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from timing gear/chain cover. 4. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 1303 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in timing gear/chain cover. 2. Install sensor (2) into timing gear/chain cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing gear/chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 Nm (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1307 Crankshaft Position Sensor: Diagrams Connector (5.7L) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (5.7L) - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description 5.7L The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 1310 Crankshaft Position Sensor: Description and Operation Operation 5.7L Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On the 5.7L V-8 engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 5.7L 1. Raise vehicle. 2. Disconnect CKP electrical connector (2) at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 1313 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking and twisting action. CAUTION: Before tightening the CKP sensor mounting bolt, be sure the sensor is completely flush to the cylinder block. If the CKP sensor is not flush, damage to the sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Removal REMOVAL 1. Disconnect negative cable from battery. 2. Remove the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 3. Remove the tilt lever handle. 4. Remove the lower shroud (2) from steering column. 5. Place shifter in PARK position. The ignition key (2) must be in the key cylinder (1) for cylinder removal. 6. A retaining pin is located at side of key cylinder assembly. a. Rotate key (2) to RUN position. b. Press in on retaining pin with a small punch (3) , while pulling key cylinder (1) from ignition switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 1319 7. Remove the key (2) and key cylinder (1) from the column (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 1320 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Installation INSTALLATION The ignition key (2) must be in the key cylinder (1) for cylinder installation. 1. Install the key cylinder (1) into the housing (3) using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder (1) in until it clicks. 3. Replace the lower shroud. 4. Install the tilt lever handle. 5. Install the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 6. Reconnect the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) Knock Sensor: Locations Knock Sensor 1 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 1325 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 1326 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 1327 Knock Sensor: Locations Knock Sensor 2 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 1328 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way Knock Sensor: Diagrams Knock Sensor 2 (3.7L/5.7L) 2 Way Connector (3.7L/5.7L) - (ENGINE) 2 WAY SENSOR-KNOCK 2 (3.7L/5.7L) - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way > Page 1331 Knock Sensor: Diagrams Knock Sensor 1 (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-KNOCK 1 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Description Knock Sensor: Description and Operation Knock Sensor - Description DESCRIPTION 3.7L - Two knock sensors (1) are bolted to the cylinder block under the intake manifold. 4.7L - One knock sensor (1) is bolted to the cylinder block under the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Description > Page 1334 5.7L - Two knock sensors (1) are bolted to each side of the cylinder block (outside) under each exhaust manifold (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Description > Page 1335 Knock Sensor: Description and Operation Knock Sensor - Operation OPERATION When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric crystal which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal 5.7L Two knock sensors (1) are used. Each sensor is bolted to the outside of the cylinder block below the exhaust manifold (3). 1. Raise the vehicle. 2. Disconnect the knock sensor electrical connector (5). 3. Remove the knock sensor mounting bolt (2). NOTE: Note the foam strip on bolt threads. This foam strip is used only to retain the bolts to the sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove the knock sensor (1) from the engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 1338 Knock Sensor: Service and Repair Knock Sensor - Installation 5.7L 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). NOTE: Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt (2). Tighten to 15 +/- 2 ft. lbs. (20 Nm) (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1344 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1345 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1346 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1347 Impact Sensor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1348 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1349 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1350 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1351 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 1352 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way Impact Sensor: Diagrams Left Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 1 - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 1355 Impact Sensor: Diagrams Left Side Impact Sensor 2 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 2 - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 1356 Impact Sensor: Diagrams Right Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-RIGHT 1 - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 1357 Impact Sensor: Diagrams Left Front Impact Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-FRONT IMPACT-LEFT - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 1358 Impact Sensor: Diagrams Left Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 1 - (BODY) 4 WAY Left Side Impact Sensor 2 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 2 - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 1359 Right Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-RIGHT 1 - (BODY) 4 WAY Left Front Impact Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 1360 SENSOR-FRONT IMPACT-LEFT - (HEADLAMP AND DASH) 2 WAY Right Front Impact Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-FRONT IMPACT-RIGHT - (HEADLAMP AND DASH) 2 WAY Right Side Impact Sensor 2 (Body) 4 Way Connector - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 1361 SENSOR-SIDE IMPACT-RIGHT 2 - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description Impact Sensor: Description and Operation Impact Sensor - Description Front FRONT Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front sensor is secured with a screw to the backs of the right and left vertical members of the radiator support within the engine compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side SIDE Four side impact sensors (1) are used on this vehicle to support the standard side curtain airbags, two each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the right or left B-pillar and quarter inner panel within the passenger compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 1364 The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 1365 Impact Sensor: Description and Operation Impact Sensor - Operation Front FRONT The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the front impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side SIDE The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through the same left or right sensor plus and minus circuits in a series arrangement from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal Impact Sensor: Service and Repair Impact Sensor - Removal Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. Remove the screw (3) that secures the right or left front impact sensor (1) to the back of the right or left radiator support vertical member (2). 3. Disconnect the headlamp and dash wire harness connector (4) from the sensor connector receptacle. 4. Remove the right or left front impact sensor from the engine compartment. Side - B-Pillar SIDE - B-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 1368 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 3. Remove the lower trim from the inside of the right or left B-pillar (1). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. 4. Remove the screw (4) that secures the side impact sensor (3) to the lower B-pillar. 5. Disconnect the body wire harness connector (2) from the sensor connector receptacle. 6. Remove the sensor from the B-pillar. Side - C/D-Pillar SIDE - C/D-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 1369 two minutes for the system capacitors to discharge before further service. 2. Remove the quarter trim panel from the quarter inner panel near the lower C-pillar (5). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Remove the screw (1) that secures the side impact sensor (2) to the quarter inner panel. 4. Disconnect the body wire harness (4) connector from the sensor connector receptacle. 5. Remove the sensor from the quarter inner panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 1370 Impact Sensor: Service and Repair Impact Sensor - Installation Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. 1. Position the right or left front impact sensor (1) into the engine compartment. 2. Reconnect the headlamp and dash wire harness connector (4) to the sensor connector receptacle. 3. Position the sensor onto the back of the right or left radiator support vertical member (2). Be certain that the anti-rotation pin on the back of the sensor is engaged in the lower clearance hole of the radiator support. 4. Install and tighten the screw (3) that secures the sensor to the back of the support vertical member. Tighten the screw to 6 Nm (55 in. lbs.). 5. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. Side - B-Pillar SIDE - B-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 1371 1. Check to be certain that the rivet nut used to secure the side impact sensor (3) is properly installed in the inner B-pillar (1),and that it is in good condition. 2. Position the side impact sensor near the inner B-pillar. 3. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 4. Position the sensor onto the inner B-pillar. Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole (5) of the B-pillar. 5. Install and tighten the screw (4) that secures the sensor to the inner B-pillar. Tighten the screw to 6 Nm (50 in. lbs.). 6. Reinstall the lower trim onto the inside of the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. 7. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. Side - C/D-Pillar SIDE - C/D-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 1372 1. Check to be certain that the rivet nut (3) used to secure the side impact sensor (2) is properly installed in the quarter inner panel, and that it is in good condition. 2. Position the side impact sensor near the quarter inner panel. 3. Reconnect the body wire harness (4) connector to the sensor connector receptacle. 4. Position the sensor onto the quarter inner panel. Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the quarter inner panel. 5. Install and tighten the screw (1) that secures the sensor to the quarter inner panel. Tighten the screw to 6 Nm (50 in. lbs.). 6. Reinstall the quarter trim panel onto the quarter inner panel near the lower C-pillar (5). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 7. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1376 Seat Belt Buckle Switch: Diagrams Connector - (LEFT SEAT) 2 WAY SWITCH-SEAT BELT-DRIVER - (LEFT SEAT) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Driver Seat Belt Switch - Description Seat Belt Buckle Switch: Description and Operation Driver Seat Belt Switch - Description DESCRIPTION The seat belt switch (4) is a small, normally open, single pole, single throw, plunger (3) actuated, momentary switch. One seat belt switch is installed on the seat belt retractor frame (2) over the retractor spool (1) for the driver side front seat. The seat belt switch includes an integral connector that is connected to the vehicle electrical system through a take out and connector of the body wire harness. The seat belt switch cannot be adjusted or repaired and, if ineffective or damaged, the entire front seat belt and retractor unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Driver Seat Belt Switch - Description > Page 1379 Seat Belt Buckle Switch: Description and Operation Driver Seat Belt Switch - Operation OPERATION The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch sense circuit to ground. Conversely, when the seat belt tip-half webbing is wound onto the retractor spool the switch plunger is depressed, opening the ground path. The EMIC monitors the seat belt switch status, then controls the illumination of the seatbelt indicator and the generation of audible electronic chime tones based upon that input. The seat belt switch receives ground through its connection to the body wire harness from another take out of the body wire harness. An eyelet terminal connector on that ground take out is secured under a ground screw. The seat belt switch is connected in series between ground and the seat belt switch sense input of the EMIC. The seat belt switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description Seat Position Sensor: Description and Operation Seat Track Position Sensor - Description DESCRIPTION The seat track position sensor (1) is a Hall Effect-type sensor. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has two integral snap features (3) and snaps into a stamped metal bracket located on the inboard side of one of the seat adjuster tracks on the front seat of vehicles so equipped. A molded connector receptacle (2) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if ineffective or damaged, the entire sensor must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description > Page 1384 Seat Position Sensor: Description and Operation Seat Track Position Sensor - Operation OPERATION The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver side front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver side front airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected. The ORC then sends messages over the Controller Area Network (CAN) data bus to control the illumination of the airbag indicator in the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The hard wired circuits between the seat track position sensor and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the seat track position sensor or the electronic controls and communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the seat track position sensor or the electronic controls and communication related to seat track position sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal Seat Position Sensor: Service and Repair Seat Track Position Sensor - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the front seat cushion to access the seat track position sensor (4) in a bracket (1) located on the inboard side of either the inner or outer, driver or passenger seat track (5). 3. Disconnect the seat wire harness connector (3) from the sensor connector receptacle located on the end of the sensor. 4. Using a small screwdriver, depress the snap feature (2) and pull the connector end of the sensor out of the bracket. 5. Remove the sensor from under the front seat. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal > Page 1387 Seat Position Sensor: Service and Repair Seat Track Position Sensor - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Reach under the front seat cushion to position the seat track position sensor (4) to the open end of the bracket (1) located on the inboard side of either the inner or outer, driver or passenger seat track (5). 2. Push the sensor firmly into the bracket until the snap feature (2) locks into place. 3. Reconnect the seat wire harness connector (3) to the sensor connector receptacle located on the end of the sensor. Be certain that the latch on the connector is fully engaged. 4. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Restraint Systems/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 1391 Seat Sensor/Switch: Diagrams Connector - (DRIVER SEAT) 2 WAY SENSOR-SEAT TRACK POSITION-DRIVER - (DRIVER SEAT) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Removal REMOVAL 1. Disconnect negative cable from battery. 2. Remove the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 3. Remove the tilt lever handle. 4. Remove the lower shroud (2) from steering column. 5. Place shifter in PARK position. The ignition key (2) must be in the key cylinder (1) for cylinder removal. 6. A retaining pin is located at side of key cylinder assembly. a. Rotate key (2) to RUN position. b. Press in on retaining pin with a small punch (3) , while pulling key cylinder (1) from ignition switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 1398 7. Remove the key (2) and key cylinder (1) from the column (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 1399 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Installation INSTALLATION The ignition key (2) must be in the key cylinder (1) for cylinder installation. 1. Install the key cylinder (1) into the housing (3) using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder (1) in until it clicks. 3. Replace the lower shroud. 4. Install the tilt lever handle. 5. Install the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 6. Reconnect the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The TPMS has been optimized for the original equipment tires and wheels. TPMS pressures have been established for the tire size equipped on your vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, and/or style. After-market wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with a TPMS, as damage to the sensors may result. NOTE: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Any time a sensor is to be reinstalled in a wheel, a new seal, cap and valve core must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION NOTE: On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 or 433 MHz radio frequency. The 315 MHz sensors can be easily identified by a black sensor body, with (an oval insignia) (1). The 433 MHz sensors can be identified by a grey sensor body with an oval insignia. NOTE: If replacing the WCM, the spare tire must be dismounted from its wheel to access and note the spare tire pressure sensor ID. Then follow the programming steps outlined in the diagnostic scan tool for "Learn Spare Tire Sensor ID" under Miscellaneous Functions for the WCM wireless control module menu item as appropriate. In addition, the placard pressure thresholds must be updated in the new WCM. Go to "Update Pressure Thresholds" under Miscellaneous Functions for the WCM wireless control module and follow the procedure. On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a black sensor body, with (an oval insignia) (1) and a grey valve cap (2). The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by a gray sensor body (with an oval insignia) and a black valve cap (2). CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Domestic vehicles, use the 315 MHz TPM sensors with the BLACK sensor body. For Export vehicles, use the 433 MHz TPM sensors with the GREY sensor body. Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct color sensor is being used. A RKE-TPM Analyzer can be used to determine the sensor's frequency without having to dismount the tire. NOTE: If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel. (This could cause sealing and system performance issues). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1407 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (4) - Valve Stem Cap (2) - Valve Stem Core - Valve Stem Nut (3) The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1408 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit if using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor's operating mode and to diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following modes: - Sleep Mode - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. - Park Mode - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 PSI delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure 30 Block Mode - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to Park Mode using a TPM-RKE Analyzer, the sensor's operating mode will transition from Park Mode to 30 Block Mode once the vehicle is driven over 15mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 8 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to Drive Mode - Drive Mode - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time that the vehicle speed drops below 15mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h). If the vehicle has been stationary for more then 20 minutes, the TPM sensor will change to PARK MODE. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 m.p.h. (24 Km/h)" after a sensor has been replaced, The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The sensor IDs can also be programmed using the TPM-RKE Analyzer Tool. Scan each TPM sensor at each road wheel, and store each Sensor ID in the correct location. (LEFT FRONT, LEFT REAR, RIGHT FRONT, and RIGHT REAR) Connect the TPM-RKE Analyzer Tool to the Scan Tool. Then follow the programming steps outlined in the diagnostic Scan Tool for "Program Tire Pressure Sensor ID w/ TPM Tool" under "MISC" for the "WCM/WIRELESS CONTROL MODULE". Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1411 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1412 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 6 Nm (53 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1413 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the outer and inner tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. 8. Remove the support and lower the vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1414 b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1420 Fluid Pressure Sensor/Switch: Diagrams Connector (4.7L/5.7L) - (ENGINE) 4 WAY SENSOR-LINE PRESSURE (4.7L/5.7L) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 1424 Overdrive Switch: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SWITCH-TOW/HAUL OVERDRIVE - (INSTRUMENT PANEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Overdrive Lockout Switch Description Overdrive Switch: Description and Operation Overdrive Lockout Switch - Description DESCRIPTION The tow/haul on control switch is located in the shift lever arm. The switch is a momentary contact device that signals the Powertrain Control Module (PCM) to toggle current status of the overdrive function. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Overdrive Lockout Switch Description > Page 1427 Overdrive Switch: Description and Operation Overdrive Lockout Switch - Operation OPERATION Tow/haul is only used in the D position. When used while towing, the electronic control module (ECU) commands hybrid system to create more positive axle torque to the wheels. When used while coasting downhill and the vehicle gains speed, the ECU commands the hybrid system to create more negative axle torque to the wheels, helping the vehicle to maintain the correct speed. The Powertrain Control Module (PCM) stores a target speed when the accelerator and brake are released, if vehicle speed increases due to a hill, then additional negative wheel torque is added to the PCMs wheel torque request. The Hybrid Control Processor (HCP) follows the PCMs command and downshifts as required to meet the negative torque request. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Overdrive Lockout Switch Removal Overdrive Switch: Service and Repair Overdrive Lockout Switch - Removal REMOVAL 1. Using a plastic trim tool (3), remove the tow/haul switch retainer (2) from the gearshift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Overdrive Lockout Switch Removal > Page 1430 Overdrive Switch: Service and Repair Overdrive Lockout Switch - Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul switch (3) into the connector (2). 3. Push the tow/haul switch (3) and wiring into the shift lever (1). 4. Install the tow/haul switch retainer onto the shift lever. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1434 Transmission Position Switch/Sensor: Diagrams Connector (HEV) - (TRANSMISSION SIDE) 12 WAY SENSOR-TRANSMISSION RANGE (HEV) - (TRANSMISSION SIDE) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Description DESCRIPTION The transmission range sensor (2) is located inside the transmission and connects to the mainshaft (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description > Page 1437 Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Disconnect the transmission range sensor electrical connector (1). 3. Remove the bolt (1) securing the transmission range sensor (2) to the mainshaft (3). 4. Remove the mainshaft roll pin (1) from the transmission case (2) and remove the mainshaft. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1440 5. Lower the transmission range sensor (2) and remove the park actuator rod (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1441 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install the park actuator rod (3) into the transmission range sensor (2). 2. Install the mainshaft roll pin (1) to the transmission case (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 1442 3. Position the transmission range sensor (2) into place in the transmission case. 4. Install the mainshaft (3) into the transmission case. 5. Install the transmission range sensor mounting bolt. Tighten the bolt to 8 Nm (71 NOTE: Before install the TEHCM / valve body assembly to the transmission case, be certain the existing gasket is in place. 6. Install the valve body. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 1447 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 1448 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way Transmission Speed Sensor: Diagrams Input Speed Sensor (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-INPUT SPEED - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way > Page 1451 Transmission Speed Sensor: Diagrams Output Speed Sensor (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-OUTPUT SPEED - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way > Page 1452 Transmission Speed Sensor: Diagrams Output Speed Sensor (HEV) Engine 2 Way Connector (HEV) - ENGINE 2 WAY SENSOR-OUTPUT SPEED (HEV) - ENGINE 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Oil Temperature Sensor - Description Transmission Temperature Sensor/Switch: Description and Operation Transmission Oil Temperature Sensor - Description DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Electronic Hydraulic Control Module (TEHCM). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Oil Temperature Sensor - Description > Page 1457 Transmission Temperature Sensor/Switch: Description and Operation Transmission Oil Temperature Sensor - Operation OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature. - Engine coolant temperature. - In-gear run time since start-up. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 1462 Four Wheel Drive Selector Switch: Diagrams Connector - (INSTRUMENT PANEL) 10 WAY SWITCH-TRANSFER CASE SELECTOR - (INSTRUMENT PANEL) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 1466 Gear Sensor/Switch: Diagrams Connector - (ENGINE) 8 WAY ASSEMBLY-SHIFT MOTOR/MODE SENSOR - (ENGINE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > Mode Sensor - Description Gear Sensor/Switch: Description and Operation Mode Sensor - Description DESCRIPTION The transfer case encoder (3) provides the Drive Train Control Module (DTCM) feedback about the position of the transfer case. The sensor consists of a linear analog position sensor that converts the motor output shaft position into a DC signal. The sensor may rotate a full 360 degrees. When the DTCM is not in sleep mode, it must supply 5 VDC (+/- 0.5 v) to the sensor and monitor the shift motor position. The sensor position is monitored when the ignition is in the RUN position and for 10 seconds after the ignition is turned to the OFF position. The sensor is mechanically linked to the shaft of the cam allowing the transfer case to shift. The mode sensor draws less than 20 mA of current during operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > Mode Sensor - Description > Page 1469 Gear Sensor/Switch: Description and Operation Mode Sensor - Operation OPERATION During normal vehicle operation, the DTCM monitors the mode sensor outputs at least every 2 milliseconds when the shift motor is stationary or active. The mode sensor position will be considered invalid by the DTCM if the voltage is greater than 4.75 V or if it is less than 0.25 V. NOTE: All the parameter voltages referred to in the following information are calibrated items in the controller software and are subject to change. The DTCM shall consider Transfer Case position based on the MODE SENSOR VOLTAGES table listed below: MODE SENSOR VOLTAGES Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Mode Sensor - Removal Gear Sensor/Switch: Service and Repair Mode Sensor - Removal REMOVAL 1. Remove the wiring harness electrical connector from the encoder. 2. Remove the screws securing the encoder to the rear transfer case housing. 3. Remove the encoder (1) from the transfer case (2). 4. Remove the O-ring seal (1) from the encoder (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Mode Sensor - Removal > Page 1472 Gear Sensor/Switch: Service and Repair Mode Sensor - Installation INSTALLATION 1. Install a NEW O-ring seal (1) onto the encoder (2). NOTE: Before installing the encoder onto the transfer case, be certain to align the encoder shaft to the shift shaft and the dowel on the encoder to the hole in the case accordingly. 2. Install the encoder (1) onto the rear transfer case housing (2). 3. Install the encoder screws. Tighten the screws to 7 Nm (62 in.lbs.). 4. Install the electrical wiring harness connector onto the encoder. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Description DESCRIPTION The switch for the rear window defogger (EBL) system (2) is integrated into the A/C-heater control (1) located in the center of the instrument panel. When the rear window defogger switch is activated, the timing circuit integral to the A/C-heater control operates the rear window defogger (EBL) relay. An amber indicator (3) in the rear window defogger switch will illuminate to indicate when the EBL system is turned on. When the EBL relay is activated, current is directed to the rear window defogger grid lines and when equipped, to the heated outside rear view mirrors. The grid lines heat the window and mirror glass to help clear the surfaces of fog or frost. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description > Page 1478 Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Operation OPERATION An amber indicator in the rear window defogger switch will illuminate when the rear window defogger switch is activated. When the switch is activated, the A/C-heater control requests the front control module (FCM) to operated the rear window defogger (EBL) relay via the controller area network (CAN) B bus. The EBL relay controls the current flow to the heating grid of the rear window and when equipped, the heated outside rear view mirrors. NOTE: The EBL system turns off automatically after approximately 15 minutes of initial operation. Each following activation cycle of the EBL system will last approximately 10 minutes. The EBL system will be automatically turned off after an initial programmed time interval of about 15 minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 10 minutes. The EBL system will also turn off if the ignition switch is turned to any position other than RUN or by manually pressing the rear window defogger switch a second time. The rear window defogger switch and indicator lamp cannot be adjusted or repaired and the A/C-heater control must be replaced if inoperative or damaged See: Heating and Air Conditioning/Control Assembly/Service and Repair/A/C and Heater Control - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 1483 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 1484 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 1485 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Left Rear Door) 6 Way Power Window Switch: Diagrams Left Rear Power Window Switch (Left Rear Door) 6 Way Connector - (LEFT REAR DOOR) 6 WAY SWITCH-POWER WINDOW-LEFT REAR - (LEFT REAR DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Left Rear Door) 6 Way > Page 1488 Power Window Switch: Diagrams Right Rear Power Window Switch (Right Rear Door) 6 Way Connector - (RIGHT REAR DOOR) 6 WAY SWITCH-POWER WINDOW-RIGHT REAR - (RIGHT REAR DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Left Rear Door) 6 Way > Page 1489 Power Window Switch: Diagrams Driver Window/Door Lock Switch C1 (Left Front Door) 8 Way Connector C1 - (LEFT FRONT DOOR) 8 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (LEFT FRONT DOOR) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Left Rear Door) 6 Way > Page 1490 Power Window Switch: Diagrams Driver Window/Door Lock Switch C2 (Left Front Door) 6 Way Connector C2 - (LEFT FRONT DOOR) 6 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (LEFT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Left Rear Door) 6 Way > Page 1491 Power Window Switch: Diagrams Passenger Window/Door Lock Switch (Right Front Door) 6 Way Connector - (RIGHT FRONT DOOR) 6 WAY SWITCH-WINDOW/DOOR LOCK-PASSENGER - (RIGHT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1492 Power Window Switch: Testing and Inspection POWER WINDOW SWITCH The front door power window switches are included in the window/lock switchSee: Sensors and Switches - Body and Frame/Power Door Lock Switch/Testing and Inspection. The Light-Emitting Diode (LED) illumination lamps for all of the power window switch knobs receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in the power window switch and the power windows are inoperative, . See: Windows and Glass/Windows/Testing and Inspection/Symptom Related Diagnostic Procedures If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. 1. Check the fuse and the circuit breaker. If OK, go to 2. If not OK, replace the fuse or circuit breaker. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fuse in the Integrated Power Module (IPM). If OK, turn the ignition switch to the OFF position and go to 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch from the door trim panel. Unplug the wire harness connector from the switch. 4. Test the power window switch continuity. See the Power Window Switch Continuity chart to determine if the continuity is correct in the Neutral, Up and Down switch positions. If OK, See: Windows and Glass/Windows/Testing and Inspection/Symptom Related Diagnostic Procedures. If not OK, replace the inoperative switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal Power Window Switch: Service and Repair Power Window Switch - Removal REMOVAL The driver and front passenger side power window switch is included in the window/lock switch. See: Sensors and Switches - Body and Frame/Power Door Lock Switch/Service and Repair/Power Lock Switch - Removal for the service procedures. 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Removal. 3. Remove switch from door trim panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal > Page 1495 Power Window Switch: Service and Repair Power Window Switch - Installation INSTALLATION The driver and front passenger side power window switch is included in the window/lock switch. See: Sensors and Switches - Body and Frame/Power Door Lock Switch/Service and Repair/Power Lock Switch - Installation. 1. Install the switch to the door trim panel. 2. Install the door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Installation. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1500 Washer Fluid Level Switch: Diagrams Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-WASHER FLUID LEVEL-FRONT REAR - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Washer Fluid Level Switch - Description Washer Fluid Level Switch: Description and Operation Washer Fluid Level Switch - Description DESCRIPTION The washer fluid level switch is a single pole, single throw reed-type switch mounted just above the sump area near the bottom of the washer reservoir. Only the molded plastic switch mounting flange and the integral connector receptacle are visible when the switch is installed in the reservoir. A short nipple formation extends from the inner surface of the switch mounting flange, and a barb on the nipple near the switch mounting flange is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. A molded plastic float rides saddle-like over a molded plastic beam that extends axially from the switch mounting flange. A small permanent magnet is secured in a receptacle on the top of the float, and the reed switch is concealed within the beam. A diagnostic resistor is connected between the two switch terminals within the switch mounting flange. The washer fluid level switch cannot be adjusted or repaired. If ineffective or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Washer Fluid Level Switch - Description > Page 1503 Washer Fluid Level Switch: Description and Operation Washer Fluid Level Switch - Operation OPERATION The washer fluid level switch uses a float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float moves, the proximity of this magnet to a stationary reed switch within the beam formation of the switch changes. When the fluid level in the washer reservoir is at or above the float level, the float rises and the influence of the float magnetic field is removed from the reed switch causing the normally open reed switch contacts to open. When the fluid level in the washer reservoir falls below the level of the float, the float falls and the influence of the float magnetic field is applied to the reed switch, causing the contacts of the normally open reed switch to close. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The switch is connected in series between ground and the washer fluid switch sense input to the Front Control Module (FCM) located in the engine compartment near the battery. The FCM monitors the switch return signal and is programmed to respond to three consecutive open switch readings by sending an electronic washer fluid indicator lamp-ON message to the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch and the hard wired circuits between the switch and the FCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer fluid level switch or the electronic controls or communication between other modules and devices that provide some features of the wiper and washer systems. The most reliable, efficient, and accurate means to diagnose the washer fluid level switch or the electronic controls and communication related to washer fluid level switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Washer Fluid Level Switch - Removal Washer Fluid Level Switch: Service and Repair Washer Fluid Level Switch - Removal REMOVAL NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Reach between the front of the left front wheel house splash shield and the front bumper support to access the rearward facing lower surface of the washer reservoir (1). 3. Disconnect the wire harness connector from the washer fluid level switch (5) connector receptacle. 4. Disconnect the front washer hose from the inboard outlet nipple (3) of the washer pump/motor unit (2) and allow the washer fluid to drain into a clean container for reuse. 5. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the reservoir. Care must be taken not to damage the reservoir. 6. Remove the switch from the reservoir. 7. Remove the rubber grommet seal from the mounting hole in the washer reservoir and discard. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Washer Fluid Level Switch - Removal > Page 1506 Washer Fluid Level Switch: Service and Repair Washer Fluid Level Switch - Installation INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (1). Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the washer fluid level switch (5) through the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be oriented downward. 4. Reconnect the wire harness connector to the switch connector receptacle. 5. Reconnect the front washer hose to the inboard outlet nipple (3) of the washer pump/motor unit (2). 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1510 Windshield Washer Switch: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Multifunction Switch - Description Windshield Washer Switch: Description and Operation Multifunction Switch - Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Front Washer Control - The multi-function switch control knob provides a momentary front WASH position for front washer system operation. - Front Wiper Control - The multi-function switch control knob provides two continuous front wipe switch positions, LOW speed or HIGH speed; and an intermittent front wipe mode with five delay interval positions. Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Multifunction Switch - Description > Page 1513 Windshield Washer Switch: Description and Operation Multifunction Switch - Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control front washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control front wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Front Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the front WASH mode. The washer pump will continue to operate in the front washer mode until the control knob is released or for 10 continuous seconds, whichever occurs first. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front washer switch status messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The FCM responds by energizing or de-energizing the washer pump in the front washer mode. - Front Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous front wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front wiper switch status messages to the FCM over the CAN data bus. The FCM responds by energizing or de-energizing the wiper on/off and high/low relays in the Power Distribution Center (PDC) for front wiper system control. - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the FCM over the CAN data bus. The FCM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the FCM over the CAN data bus. The FCM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the FCM over the CAN data bus. The FCM energizes and flashes or de-energizes the selected left or right turn signal circuits. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 1514 Windshield Washer Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the multi-function switch from the switch mounting housing on the steering column. See: Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Multifunction Switch - Removal. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Multifunction Switch - Removal Windshield Washer Switch: Service and Repair Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 1517 8. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 9. Rotate the steering wheel far enough to access and remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 10. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 1518 Windshield Washer Switch: Service and Repair Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Rotate the steering wheel far enough to install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. Be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 1519 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1523 Wiper Switch: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Multifunction Switch - Description Wiper Switch: Description and Operation Multifunction Switch - Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Front Washer Control - The multi-function switch control knob provides a momentary front WASH position for front washer system operation. - Front Wiper Control - The multi-function switch control knob provides two continuous front wipe switch positions, LOW speed or HIGH speed; and an intermittent front wipe mode with five delay interval positions. Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Multifunction Switch - Description > Page 1526 Wiper Switch: Description and Operation Multifunction Switch - Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control front washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control front wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Front Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the front WASH mode. The washer pump will continue to operate in the front washer mode until the control knob is released or for 10 continuous seconds, whichever occurs first. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front washer switch status messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The FCM responds by energizing or de-energizing the washer pump in the front washer mode. - Front Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous front wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front wiper switch status messages to the FCM over the CAN data bus. The FCM responds by energizing or de-energizing the wiper on/off and high/low relays in the Power Distribution Center (PDC) for front wiper system control. - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the FCM over the CAN data bus. The FCM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the FCM over the CAN data bus. The FCM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the FCM over the CAN data bus. The FCM energizes and flashes or de-energizes the selected left or right turn signal circuits. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 1527 Wiper Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the multi-function switch from the switch mounting housing on the steering column. See: Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Multifunction Switch - Removal. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch - Removal Wiper Switch: Service and Repair Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 1530 8. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 9. Rotate the steering wheel far enough to access and remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 10. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 1531 Wiper Switch: Service and Repair Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Rotate the steering wheel far enough to install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. Be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 1532 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment Alignment: Specifications Wheel Alignment WHEEL ALIGNMENT NOTE: All alignment specifications are in degrees. 4X2 4x4 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment > Page 1538 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Wheel Alignment > Page 1539 Alignment: Specifications Curb Height Measurement FRONT CURB HEIGHT MEASUREMENT Difference between spindle and control arm bolt to ground distances should be 81 mm +/- 3.2 mm (3.18 in +/- 0.12 in) REAR CURB HEIGHT MEASUREMENT The difference between the jounce bumper landing pad and the jounce bumper cup lip. The reading should be 148 mm +/-10 mm (5.8 in +/- 0.40 in) for 9.25" axle, 154 mm +/-10 mm (6.0 in +/0.40 in) for 8.25" axle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Description Alignment: Description and Operation Description DESCRIPTION NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur. Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Description > Page 1542 Alignment: Description and Operation Operation OPERATION - CASTER (1) is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns. - CAMBER (2) is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. - TOE (4) is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's unstable steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel alignment adjustment. - THRUST ANGLE (3) is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1543 Alignment: Testing and Inspection PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart below for additional information. NOTE: Vehicle should have a full tank of fuel prior to measuring and adjusting alignment. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. Check suspension ride height. 7. Road test the vehicle. SUSPENSION AND STEERING SYSTEM DIAGNOSIS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Height Measurement Alignment: Service and Repair Height Measurement HEIGHT MEASUREMENT The vehicle suspension height MUST be measured and adjusted before performing wheel alignment procedure. Also when front suspension components have been replaced. This measure must be performed with the vehicle supporting it's own weight and taken on both sides of the vehicle. NOTE: Vehicle should have a full tank of fuel prior to measuring and adjusting alignment. FRONT CURB HEIGHT MEASUREMENT 1. Inspect tires and set to correct pressure. 2. Jounce the front of the vehicle. 3. With vehicle on level ground or hoist, make the following measurements: a. Front wheel spindle (center) (1) to ground vertical distance (3). b. Center of the front face of bolt on the rear leg of Lower control arm (2) to ground vertical distance (3). c. Difference between spindle and control arm bolt to ground distances should be 81 mm +/- 3.2 mm (3.18 in +/- 0.12 in)Note that the control arm bolt is lower than the spindle. 4. If adjustment is required, turn the torsion bar adjuster bolts- if lowering curb height, unscrew Torsion bar adjuster bolt beyond desired point so as to set height when screwing-in adjuster bolt. 5. After making any curb height adjustment, roll vehicle preferably jouncing it also, to relieve camber Effects and then re-measure Lower control arm bolt to ground height. 6. Repeat the previous steps until the curb height is within specifications. REAR CURB HEIGHT MEASUREMENT 1. Inspect tires and set to correct pressure. 2. Jounce the front of the vehicle. 3. With vehicle on level ground or hoist, make the following measurements: a. Distance from the landing pad of the jounce bumper on the axle side to the jounce bumper cup lip of the frame side. b. The difference between the jounce bumper landing pad and the jounce bumper cup lip. The reading should be 148 mm +/-10 mm (5.8 in +/0.40 in) for 9.25" axle, 154 mm +/-10 mm (6.0 in +/- 0.40 in) for 8.25" axle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Height Measurement > Page 1546 Alignment: Service and Repair Height Adjustment HEIGHT ADJUSTMENT The vehicle suspension height MUST be measured and adjusted before performing wheel alignment procedure See: . Also when front suspension components have been replaced. This measurement must be performed with the vehicle supporting it's own weight and taken on both sides of the vehicle. To adjust the vehicle height turn the torsion bar adjustment bolt CLOCKWISE to raise the vehicle and COUNTER CLOCKWISE to lower the vehicle. CAUTION: ALWAYS raise the vehicle to the correct suspension height, NEVER lower the vehicle to obtain the correct suspension height. If the vehicle suspension height is too high, lower the vehicle below the height specification. Then raise the vehicle to the correct suspension height specification. This will insure the vehicle maintains the proper suspension height. NOTE: If a height adjustment has been made, perform height measurement again on both sides of the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Height Measurement > Page 1547 Alignment: Service and Repair Camber, Caster and Toe Adjustment CAMBER, CASTER AND TOE ADJUSTMENT NOTE: Suspension height measurement must be performed before an alignment. Camber and caster angle adjustments involve changing the position of the lower control arm with the slots in the frame brackets to move the lower control arm inwards or outwards for proper adjustment. This can be achieved by using a long pry bar with a curved tip and inserting the pry bar into the lower control arm frame brackets and prying inwards or outwards. NOTE: Camber and caster adjustments must be made at the lower control arm. Do not use the upper control arm for Camber and Caster adjustments. NOTE: When the lower control arm pivot bolts are loosened the lower control arm will normally go outwards automatically with the weight of the vehicle. CASTER Moving the rear position of the lower control arm at the frame in or out, will change the caster angle significantly and camber angle only slightly. To maintain the camber angle while adjusting caster, move the rear of the lower control arm in or out. Then move the front of the lower control arm slightly in the opposite direction. CAMBER Move both the front and rear of the lower control arm together in or out. This will change the camber angle significantly and caster angle slightly. After adjustment is made tighten the lower control arm bolt AND nuts to 244 Nm (180 ft. lbs.). TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts (3). NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the inner tie rod (4) as necessary. 4. Tighten the tie rod jam nut (3) to 130 Nm (96 ft. lbs.). 5. Verify the specifications. 6. Turn off engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE The correct fuel pressure for this vehicle is 58 psi +/- 2 psi Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1552 Fuel Pressure: Testing and Inspection FUEL PRESSURE LEAK DOWN For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: Follow these safety precautions to reduce the risk of fire and serious possible serious or fatal injury when performing this test procedure. Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. Use extreme caution when connecting and disconnecting fuel lines. - Considerable fuel leakage may occur when servicing the fuel system. Wear protective eye wear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair / replace as necessary. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A 1. Turn the ignition off. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1553 WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from Gas and Diesel Fuel Pressure/Decay Tester 8978A. Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978A-1 (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect the Reservoir Assembly 534960 (4) to the Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1554 - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 2. Turn the ignition on, wait five seconds, turn the ignition off and then wait 1 minute before proceeding. 3. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 Kpa +/- 34 Kpa (59 psi +/- 5 psi). SRT-4 fuel pressure specification is 552 Kpa +/- 34 Kpa (80 psi +/- 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the Checking The Fuel Delivery System diagnostic procedure as directed. 5. CHECK FUEL DELIVERY SYSTEM FOR LEAK DOWN WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Close the Fuel System Isolation Valve (1) and then wait five minutes before proceeding. 2. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge (1) - Replace the fuel pump module. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Yes - On Fuel Outlet Gauge (2) - Replace the leaking fuel injector(s). - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. No - If directed here by another test, return to that test. Otherwise, test complete. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal Air Filter Element: Service and Repair Air Cleaner - Removal REMOVAL - AIR FILTER ELEMENT - HEV 1. Remove the air cleaner trim covers (2) with a small screwdriver (1). 2. Remove the air clean cover fasteners (1). 3. Unclip the air cleaner cover latches (2). 4. Remove the air cleaner cover (3). 5. Remove the air filter element (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 1560 Air Filter Element: Service and Repair Air Cleaner - Installation INSTALLATION - AIR FILTER ELEMENT - HEV 1. Install a new filter element (1). 2. Install the air cleaner cover (3). 3. Install the air cleaner cover fasteners (1). 4. Secure the air cleaner cover latches (2). 5. Install the air cleaner trim covers (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions Use the following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove the fuel fill cap. 2. Remove the fuel pump relay or the fuel pump speed relay from the Power Distribution Center (PDC) (1), refer to the label on the underside of the PDC cover for relay locations or See: Fuses and Circuit Breakers/Fuse/Locations/Fuse Panel 3. Start and run the engine until it stalls. 4. Attempt restarting the engine until it will no longer run. 5. Turn the ignition key to the OFF position. 6. Disconnect the 12 volt battery system ground isolation connector (1). 7. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down NOTE: Excessive fuel spillage onto the gaskets can cause gaskets to expand and dislodge from gasket groove. 8. Place a rag or towel around the fuel line quick-connect fitting at the fuel rail to prevent residual fuel spray or spillage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1565 9. Disconnect the fuel supply line quick connect fitting at the fuel rail (1) and plug the fuel supply line with a shipping cap See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair 10. Return the fuel pump relay or the fuel pump speed relay to the PDC. NOTE: One or more Diagnostic Trouble Code(s) (DTC) may have been stored in the PCM memory due to the fuel pump relay removal. A diagnostic scan tool must be used to erase a DTC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications ENGINE FIRING ORDER - 5.7L The firing order for the 5.7L V-8 is 1-8-4-3-6-5-7-2. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications IGNITION TIMING Ignition timing is not adjustable on any of the available engines. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications Spark Plug: Specifications Spark Plug Specifications SPARK PLUGS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications > Page 1576 Spark Plug: Specifications Torque SPARK PLUG TORQUES Spark Plugs - 3.7L................................................................................................................................ .......................................................27 Nm (20 ft. lbs.) Spark Plugs - All 4.7L (Upper or Lower row) (New plugs/gaskets).......................................................................................................27±3 Nm (20 ft. lbs.) Spark Plugs - All 4.7L (Upper or Lower row) (Used plugs/gaskets).......................................................................................................22±3 Nm (16 ft. lbs.) **Spark Plugs - 5.7L............................................................................................................................. ........................................ 18(±3) Nm (13(±2) ft. lbs.) ** Torque critical tapered design. Do not exceed 15 ft.lbs. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal Spark Plug: Service and Repair Spark Plug - Removal 5.7L 1. Remove all the necessary air filter tubing and air intake components at the top of the engine and at the throttle body See: Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal 2. Prior to removing the ignition coil, spray compressed air around the base of the ignition coil at the cylinder head. 3. Remove the ignition coil (1) See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil - Removal 4. Prior to removing the spark plug, spray compressed air into the cylinder head opening. 5. Remove the spark plug from the cylinder head using a quality thin wall socket with a rubber or foam insert. 6. Inspect the spark plug condition. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 1579 Spark Plug: Service and Repair Spark Plug - Installation 5.7L CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. CAUTION: Do not attempt to clean any of the spark plugs. Replace only. 1. Check and adjust the spark plug gap with a gap gauging tool (1) See: Specifications/Spark Plug Specifications. CAUTION: Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. 2. Start the spark plug into the cylinder head by hand to avoid cross threading. NOTE: Always tighten spark plugs to the specified torque. Certain engines use torque sensitive spark plugs. Over tightening can cause distortion resulting in a change in the spark plug gap, or a cracked porcelain insulator. NOTE: Spark plugs have a torque critical tapered design. Do not exceed 20 Nm (15 ft. lbs.). 3. Tighten the spark plugs to 18 Nm (13 ft. lbs.). 4. To aid in coil installation, apply silicone based grease such as Mopar(R) Dielectric Grease into spark plug end of ignition coil rubber boots. Also apply this grease to the tops of spark plugs. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 1580 5. Install the ignition coil(s) (1) See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil - Installation 6. Install all necessary air filter tubing and air intake components to top of engine and to throttle body See: Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications PRESSURE/VARIATION Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1584 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE LEAKAGE NOTE: The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. NOTE: Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs and record the cylinder number of each spark plug for future reference. 3. Inspect the spark plug electrodes for abnormal firing indicators such as fouled, hot, oily, etc. 4. Disable the fuel system See: Fuel Filter/Fuel Pressure Release/Service and Repair and perform the fuel system pressure release procedure. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 7. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 8. If one or more cylinders have abnormally low compression pressures, repeat the compression test. NOTE: If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. 9. If one or more cylinders continue to have abnormally low compression pressures, perform the cylinder combustion pressure leakage test See: Engine, Cooling and Exhaust/Engine/Testing and Inspection/Component Tests and General Diagnostics/Cylinder Combustion Pressure Leakage Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation Drive Belt: Description and Operation ACCESSORY DRIVE BELT The accessory drive belt is a serpentine type belt. Satisfactory performance of these belts depends on belt condition and proper belt tension. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 1588 Drive Belt: Testing and Inspection ACCESSORY DRIVE BELT VISUAL DIAGNOSIS When diagnosing the accessory drive belt, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer toACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. ACCESSORY DRIVE BELT DIAGNOSIS CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 1589 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Description and Operation > Page 1590 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures Drive Belt: Procedures CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease and coolants before installing the drive belt. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Procedures > Page 1593 Drive Belt: Removal and Replacement Serpentine Accessory Drive Belt - Removal 5.7L HEV ENGINE 1. Raise and support the vehicle. 2. Using hand tools (3) , rotate the crankshaft clockwise, walking the water pump drive belt (2) off of the crankshaft pulley (1). Serpentine Accessory Drive Belt - Installation 5.7L HEV ENGINE 1. Position the drive belt (1) onto the crankshaft pulley (1). Make sure the belt is fully seated in the grooves. 2. Start the drive belt (1) onto the water pump pulley. 3. Working from the back side of the water pulley, insert a nylon wire tie, 196.85X3.175X1.27mm (7.75X0.125x0.050 in.), through one of the holes in the pulley. CAUTION: Do not use a wire tie with a metal locking tab. 4. Tighten the wire tie to hold the drive belt in position. 5. While holding the drive belt to make sure it stays in position, using a ratchet and socket (3), slowly rotate the engine clockwise. 6. Once the belt is in position on the pulley, continue rotating the engine until the wire tie snaps. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal Air Filter Element: Service and Repair Air Cleaner - Removal REMOVAL - AIR FILTER ELEMENT - HEV 1. Remove the air cleaner trim covers (2) with a small screwdriver (1). 2. Remove the air clean cover fasteners (1). 3. Unclip the air cleaner cover latches (2). 4. Remove the air cleaner cover (3). 5. Remove the air filter element (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 1600 Air Filter Element: Service and Repair Air Cleaner - Installation INSTALLATION - AIR FILTER ELEMENT - HEV 1. Install a new filter element (1). 2. Install the air cleaner cover (3). 3. Install the air cleaner cover fasteners (1). 4. Secure the air cleaner cover latches (2). 5. Install the air cleaner trim covers (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair FLUID AND FILTER REPLACEMENT WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. REMOVAL 1. Raise and support the vehicle. See: Vehicle Lifting/Service and Repair. 2. Disconnect the transmission auxiliary oil pump electrical connector. 3. Remove the bolt (1) securing the auxiliary oil pump harness (2) to the transmission bellhousing (3). 4. Remove the transmission auxiliary oil pump bolts (1) and then remove the pump (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1604 5. Place a suitable container under the transmission pan (1). 6. Remove the drain plug, if equipped. 7. Remove bolts holding front and sides of oil pan to transmission. 8. Loosen bolts holding rear of oil pan to transmission. 9. Slowly separate front of oil pan (1) away from transmission (4), allowing the fluid to drain into the drain pan. 10. Supporting the oil pan, remove remaining bolts securing pan to transmission. 11. While holding the oil pan level, lower it from transmission. 12. Pour any remaining fluid in pan into drain pan. 13. Separate the primary (2) and auxiliary (3) oil filters from valve body and oil pump and pour fluid from the filters into drain pan. 14. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove with a suitable tool, and discard the oil filter seals from the bottom of the oil pump. If the seals are installed correctly and are in good condition, they can be reused. 15. Dispose of used transmission fluid and filter(s) properly. INSPECTION Inspect the bottom of the oil pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the oil pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and oil pan are contaminated with excessive amounts of debris, refer to the diagnosis section. CLEANING 1. Using a suitable solvent, clean the oil pan and magnet. INSTALLATION CAUTION: The primary and auxiliary oil filter seals MUST be fully installed flush against the oil pump body. DO NOT install the seals onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install new primary (2) and auxiliary (2) oil filter seals in the oil pump inlet bore. Seat the seal in the bore with Installer 6960 or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place new primary (2) and auxiliary (3) oil filters in position on valve body and into the oil pump. 3. Position the oil pan (1) on transmission. 4. Install bolts to secure pan to transmission. Tighten the oil pan bolts to 27 Nm (20 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1605 5. Install the auxiliary oil pump (2). Install the bolts (1) and tighten to 11 Nm (8 ft. lbs.). 6. Install the bolt (1) securing the auxiliary oil pump harness (2) to the transmission bellhousing (3). Tighten the bolt to 11 Nm (8 ft. lbs.). 7. Connect the auxiliary oil pump electrical connector. 8. Lower the vehicle and remove. 9. Fill the transmission with DEXRON(R) VI. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Procedures/Transmission Fill Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions Use the following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove the fuel fill cap. 2. Remove the fuel pump relay or the fuel pump speed relay from the Power Distribution Center (PDC) (1), refer to the label on the underside of the PDC cover for relay locations or See: Fuses and Circuit Breakers/Fuse/Locations/Fuse Panel 3. Start and run the engine until it stalls. 4. Attempt restarting the engine until it will no longer run. 5. Turn the ignition key to the OFF position. 6. Disconnect the 12 volt battery system ground isolation connector (1). 7. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down NOTE: Excessive fuel spillage onto the gaskets can cause gaskets to expand and dislodge from gasket groove. 8. Place a rag or towel around the fuel line quick-connect fitting at the fuel rail to prevent residual fuel spray or spillage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 1610 9. Disconnect the fuel supply line quick connect fitting at the fuel rail (1) and plug the fuel supply line with a shipping cap See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair 10. Return the fuel pump relay or the fuel pump speed relay to the PDC. NOTE: One or more Diagnostic Trouble Code(s) (DTC) may have been stored in the PCM memory due to the fuel pump relay removal. A diagnostic scan tool must be used to erase a DTC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Procedures Oil Filter: Procedures ENGINE OIL SERVICE The engine oil level indicator is located at the left hand of the engine on the 5.7L engines. CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result. Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about ten minutes before checking oil level. Checking engine oil level on a cold engine is not accurate. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately five minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the ADD mark on dipstick. ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance SchedulesSee: . Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged. 6. Install drain plug in crankcase. Torque to 34 Nm ( 25 ft. lbs.). 7. Lower vehicle and fill crankcase with specified type and amount of engine oil described. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. NOTE: Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING at beginning of this section. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Service and Repair > Procedures > Page 1615 Oil Filter: Removal and Replacement Engine Oil Filter - Removal REMOVAL All engines are equipped with a high quality full-flow, disposable type oil filter. Chrysler Corporation recommends a Mopar(R) or equivalent oil filter be used. 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter. 3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter. 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. Engine Oil Filter - Installation INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one half turn, or 180°,do not over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Water Pump Inlet Tube - Removal Coolant Line/Hose: Service and Repair Water Pump Inlet Tube - Removal WATER INLET TUBE 1. Disconnect the battery negative cable. 2. Partially drain the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 3. Remove the upper radiator hose at the radiator. 4. Unplug the wiring harness from the A/C compressor. 5. Remove the air cleaner assembly See: Filters/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. 6. Remove the accessory drive belt See: Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 7. Remove the bracket-to-intake manifold bolts. The drive belt idler pulley must be removed to gain access to one of the A/C compressor/generator bracket mounting bolts (3). 8. Remove the idler pulley bolt and the remove idler pulley. 9. Remove the oil dipstick tube mounting bolt (3) at the side of the A/C-generator mounting bracket. 10. Disconnect the throttle body cables. 11. Remove the heater hose from the heater hose return tube. 12. Remove the heater hose return tube mounting bolt and remove the tube (4) from the engine. Discard the tube O-ring. 13. Remove the six bracket bolts. 14. Lift and position the generator and the A/C compressor (along with their common mounting bracket) to gain access to the bypass hose. 15. Loosen and position both hose clamps to the center of the bypass hose. Remove the hose from vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Water Pump Inlet Tube - Removal > Page 1621 Coolant Line/Hose: Service and Repair Water Pump Inlet Tube - Installation WATER INLET TUBE 1. Position the bypass hose clamps to the center of the hose. 2. Install the bypass hose to the engine. 3. Secure both hose clamps. 4. Install the generator-A/C mounting bracket assembly to the engine. Tighten bolts (number 1 and 2 ) to 54 Nm (40 ft. lbs.). Tighten bolts (number 3 ) to 40 Nm (30 ft. lbs.). 5. Install a new O-ring to the heater hose return tube. Coat the new O-ring with antifreeze before installation. 6. Install the coolant return tube and its mounting bolt to engine. 7. Connect the throttle body control cables. 8. Install the oil dipstick mounting bolt. 9. Install the idler pulley. Tighten the bolt to 54 Nm (40 ft. lbs.). 10. Install the drive belt See: Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. 11. Install the air cleaner assembly See: Filters/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation. 12. Install the upper radiator hose to radiator. 13. Connect the wiring harness to the A/C compressor. 14. Connect the battery negative cable. 15. Fill the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 16. Start and warm the engine. Check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description Hose/Line HVAC: Description and Operation A/C Discharge Line - Description DESCRIPTION The A/C discharge line (1) is the refrigerant line that carries refrigerant from the A/C compressor to the A/C condenser (2) and is secured to the condenser fan shroud (4) by a plastic retainer (3). The A/C discharge line has an integral fitting for the A/C pressure transducer (5) See: Heating and Air Conditioning/Refrigerant Pressure Sensor / Switch/Description and Operation/Front A/C Pressure Transducer - Description. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C discharge line has no serviceable parts except for the rubber O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C discharge line is disconnected. The A/C discharge line cannot be repaired and must be replaced if leaking or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 1626 Hose/Line HVAC: Description and Operation A/C Liquid Line - Description Front DESCRIPTION The A/C liquid line is the refrigerant line that carries refrigerant from the A/C condenser to the A/C evaporator. The A/C liquid line is serviced in two sections. The front section of the liquid line (1) connects between the A/C condenser and the receiver/drier (2). The rear section of the liquid line (3) connects between the A/C receiver/drier and the A/C expansion valve (7) and includes the high side service port (5) and a tapping plate (8) that secures the suction line (9) to the A/C expansion valve. On models equipped with the rear heating-A/C system, the rear section of the A/C liquid line also includes an extension tube that connects the liquid line to the underbody lines . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C liquid line has no serviceable parts except for the rubber O-ring seals, high-side service port valve, cap and retainer clip (4). The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the liquid line is disconnected. The A/C liquid line cannot be repaired and must be replaced if leaking or damaged. Rear DESCRIPTION The rear A/C liquid line (1) is the refrigerant line that carries refrigerant from the A/C condenser to the rear A/C evaporator. The rear A/C liquid line Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 1627 serviced in two sections and includes a tapping plate (4) that retains the A/C suction line (3) . Models equipped with the rear heating-A/C system include an extension tube (8) that connects the liquid line to the underbody line by use of a spring-lock type refrigerant line coupler (6) and a secondary retaining clip (7). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The rear A/C liquid line has no serviceable parts except for the rubber O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C liquid line is disconnected. The rear A/C liquid line cannot be repaired and must be replaced if leaking or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 1628 Hose/Line HVAC: Description and Operation A/C Suction Line - Description Front DESCRIPTION The A/C suction line (9) is the refrigerant line that carries refrigerant from the A/C evaporator to the A/C compressor. The A/C suction line includes the low side service port (6) and is secured to the A/C expansion valve (7) by the liquid line tapping plate (8). On models equipped with the rear heating-A/C system, the A/C suction line also includes an extension tube that connects the suction line to the underbody lines . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C suction line has no serviceable parts except for the rubber O-ring seals, low-side service port valve and cap. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C suction line is disconnected. The A/C suction line cannot be repaired and must be replaced if leaking or damaged. Rear DESCRIPTION The rear A/C suction line (3) is the refrigerant line that carries refrigerant from the rear A/C evaporator to the A/C compressor. The rear A/c suction line is retained into the liquid line tapping block (4) by a plastic retainer . Models equipped with the rear heating-A/C system include an extension tube (5) that connects the suction line to the underbody line by use of a spring-lock type refrigerant line coupler (6) and a secondary retaining clip (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 1629 NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The rear A/C suction line has no serviceable parts except for the rubber O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C suction line is disconnected. The rear A/C suction line cannot be repaired and must be replaced if leaking or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 1630 Hose/Line HVAC: Description and Operation A/C Underbody Lines - Description DESCRIPTION Models equipped with the rear heating-A/C system use metal lines (1) attached to the vehicle underbody (2) to carry refrigerant and engine coolant to/and from the rear A/C evaporator and heater core. The underbody A/C lines are connected to the front A/C suction and liquid lines by spring-lock type couplers and secondary retaining clips See: Heating and Air Conditioning/Coupler HVAC/Description and Operation/Refrigerant Line Coupler - Description and to the rear HVAC housing (3) by a tapping plate (4) and nut (5). The metal underbody heater lines have rubber hose ends that are connected to the front heater hoses and the rear HVAC housing by use of spring-clamp type heater hose clamps. The underbody lines are retained by plastic mounting brackets (6) and screws (7) and can be repaired (depending on the amount of damage) by using A/C Line Repair Tool Kit 8456A or equivalent See: Service and Repair/Procedures. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The underbody lines can only be removed by lifting the body off of the frame and have no serviceable parts except for the refrigerant line rubber O-ring seals and the mounting brackets. The O-ring seals used on the refrigerant line connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the underbody refrigerant lines are disconnected. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures Hose/Line HVAC: Procedures UNDERBODY LINE REPAIR WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. WARNING: This procedure is intended for underbody line repair only. Use of the connector fittings and A/C Line Repair Tools 8456A on any other type of vehicle tubing may cause tube failure resulting in possible serious or fatal injury. 1. If repairing an underbody refrigerant line, recover the refrigerant from the refrigerant system See: Fluids/Refrigerant/Service and Repair. 2. If repairing an underbody coolant line, drain the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 3. Disconnect and isolate the negative battery cable. 4. Raise and support the vehicle. 5. Remove the underbody mounting brackets as necessary to gain access to the underbody line(s) needing repair See: Removal and Replacement/A/C Underbody Lines - Removal. 6. Mark the cut location(s) on the underbody line(s) needing repair. Check the Tube Length chart for the minimum amount of straight tube required (dimension A) for proper connector fitting installation. 7. Using a small pipe cutter or another suitable tool, carefully cut the underbody line(s) needing repair at the location(s) previously marked. TUBE LENGTH Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1633 8. Size a replacement line, same size diameter and length as the portion of the line(s) removed. NOTE: A minimum of 28.5 mm (3/4 in) of the line end must be cleaned in order for the connector fitting to properly seal the repair area. 9. Clean the ends of the line(s) a minimum of 28.5 mm (3/4 in) (dimension A) using the Scotch-Bright (R) pad provided with A/C Line Repair Tools 8456A. Clean the line end(s) with a rotational motion around the line to avoid longitudinal scratches in the line. 10. Select the proper connector fitting (1) for the size of the underbody line being repaired. Refer to the Connector Fitting chart. 11. Apply one drop of Lokprep(R) sealing compound provided with A/C Line Repair Tools 8456A onto each line end (2). 12. Insert the line ends into the selected connector fitting and rotate the connector fitting a complete turn to evenly distribute the sealing compound. CONNECTOR FITTING Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1634 13. Select the proper size jaws (1) for the line being repaired from the A/C Line Repair Tools 8456A. Refer to the Jaw Size chart. 14. Assemble the jaws into Tool Body 8456-3 (2) (in Kit 8456A). a. For standard installation, install the jaws with the rubber gripping pads (3) facing outward. See the Tube Length chart. b. For reversed installation, remove the rubber gripping pads and install the jaws with the rubber gripping pad area facing inward. See the Tube Length chart. JAW SIZE NOTE: The connector fitting ends must be positioned into the counterbore of the jaws in order for the connector fitting to properly seal the repair area. 15. Install the connector fitting (1) and the line ends (4) into the counterbore of the jaws (5). 16. Hold Tool Body 8456-3 (2) with a 3/8 inch breaker bar and turn the forcing screw (3) clockwise. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1635 NOTE: The lines must be kept fully inserted into the connector fitting to obtain a leak free joint. 17. Turn the forcing screw (1) clockwise until both connector fitting collars (2) have bottomed out on the center shoulder of the connector (3). 18. Loosen the forcing screw and remove Tool Body 8456-3 (4) and the jaws (5) from the repaired line(s). 19. Install the underbody mounting brackets as necessary See: Removal and Replacement/A/C Underbody Lines - Installation. 20. Lower the vehicle. 21. Reconnect the negative battery cable. 22. If repairing an underbody coolant line, refill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 23. If repairing an underbody refrigerant line, evacuate and charge the refrigerant systemSee: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1636 Hose/Line HVAC: Removal and Replacement A/C Discharge Line - Removal 5.7L ENGINES WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: Typical A/C discharge line shown. 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 4. Disconnect the wire harness connector (6) from the A/C pressure transducer (5). 5. If required, remove the A/C pressure transducer from the A/C discharge line (1). 6. Remove the nut (7) that secures the A/C discharge line to the A/C condenser (2). 7. Disconnect the A/C discharge line from the A/C condenser and the retainer (3) located on the condenser fan shroud (4). 8. Remove the O-ring seal and gasket from the discharge line fitting and discard. 9. Install plugs in, or tape over, the discharge line fitting and condenser port. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1637 NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 10. If required, raise and support the vehicle. 11. Remove the nut (6) that secures the A/C discharge line (1) to the A/C compressor (5). CAUTION: On HEV models, a small quantity of refrigerant oil may be lost from the A/C compressor when the A/C discharge line is disconnected. Prior to removing the A/C discharge line from the A/C compressor, it very important to place a small clean container below the discharge line fitting to capture any refrigerant oil that may leak from the compressor discharge port. Always measure the amount of refrigerant oil lost and replace with the same amount of fresh clean ND-11 POE refrigerant oil prior to recharging the A/C system. Never use PAG oil in an HEV model or operate the A/C system with an incorrect amount of oil in the system. Failure to follow this caution may result in serious damage to the HEV A/C system. 12. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal and gasket. 13. Install plugs in, or tape over, the opened refrigerant line fitting and the compressor port. 14. Remove the A/C discharge line from the engine compartment. A/C Discharge Line - Installation 5.7L ENGINES CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: Always use ND-11 Polyester (POE) oil from Mopar(R) in Hybrid Electric Vehicle (HEV) models. Never use Polyalkylene Glycol (PAG) oil in an HEV model. See Refrigerant Oil for more information. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1638 NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 1. Position the A/C discharge line (1) into the engine compartment. 2. Remove the tape or plugs from the opened discharge line fitting and the compressor port. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Install the A/C discharge line onto the A/C compressor (5). 5. Install the nut (6) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 23 Nm (17 ft. lbs.). NOTE: Typical A/C discharge line shown. 6. If required, lower the vehicle 7. Remove the tape or plugs from the opened discharge line fitting (1) and the condenser port (2). 8. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 9. Install the A/C discharge line to the A/C condenser and the retainer (3) located on the condenser fan shroud. 10. Install the nut (7) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 22 Nm (16 ft. lbs.). 11. If removed, install the A/C pressure transducer (5) onto the A/C discharge line. 12. Connect the wire harness connector (6) to the A/C pressure transducer. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 13. On HEV models, reconnect the battery system using the service disconnect at the battery pack . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 14. On gasoline only models, reconnect the negative battery cable. 15. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1639 CAUTION: On HEV models, a small quantity of refrigerant oil may have been lost from the A/C compressor when the A/C discharge line was disconnected. Always replace the lost oil with the same amount of fresh clean ND-11 POE refrigerant oil prior to recharging the A/C system. Never use PAG oil in an HEV model or operate the A/C system with an incorrect amount of oil in the system. Failure to follow this caution may result in serious damage to the HEV A/C system. 16. Adjust the refrigerant oil level See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity. 17. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Front REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: The A/C liquid line is serviced in two sections. The front section connects between the A/C condenser and the receiver/drier. The rear section connects between the receiver/drier and the A/C expansion valve. On models equipped with the rear heating-A/C system, the rear section of the A/C liquid line also includes an extension tube that connects the liquid line to the underbody lines. FRONT SECTION 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 4. Remove the air cleaner housing and resonator (1) See: Filters/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1640 5. Remove the bolt (1) that secures the front section of the A/C liquid line (2) to the receiver/drier (3). 6. Disconnect the front section of the A/C liquid line from the receiver/drier and remove and discard the O-ring seal. 7. Install plugs in, or tape over, the opened liquid line fitting and receiver/drier port. 8. Remove the nut (1) that secures the front section of the A/C liquid line (2) to the A/C condenser (3). 9. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 10. Install plugs in, or tape over, the opened liquid line fitting and condenser port. 11. Remove the front section of the A/C liquid line from the engine compartment. REAR SECTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1641 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 4. Remove the air cleaner housing and resonator (1) See: Filters/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. 5. Remove the rear section of the A/C liquid line (2) from the plastic retainer (3) located on the right inner fender (4). 6. On HEV models, drain the coolant for the Traction Power Inverter Module (TPIM) (1) and remove the coolant recovery bottle See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/TPIM Coolant Recovery Container - Removal. 7. Remove the TPIM and mounting bracket (2) to gain access to the A/C liquid line See: Hybrid Drive Systems/Power Control System/Voltage Inverter/Service and Repair/Traction Power Inverter Module - Removal. 8. Remove the bolt (1) that secures the rear section of the A/C liquid line (2) to the receiver/drier (3). 9. Disconnect the rear section of the A/C liquid line from the receiver/drier and remove and discard the O-ring seal. 10. Install plugs in, or tape over the opened liquid line fitting and the receiver/drier port. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1642 11. Raise and support the vehicle. 12. Remove the right front wheelhouse splash shield. 13. Remove the plastic retainer (1) that secures the A/C suction line (2) to the liquid line tapping block (4). 14. Remove the nut (3) that secures the liquid line tapping block to the A/C expansion valve (5). 15. Disconnect the A/C suction line and the rear section of the A/C liquid line from the A/C expansion valve and remove and discard the O-ring seals and gaskets. 16. Install plugs in, or tape over the opened refrigerant line fittings and the expansion valve ports. 17. Separate the A/C suction line from the liquid line tapping block. 18. On models equipped with the rear heating-A/C system, disconnect the underbody liquid line from the liquid line tapping block See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Removal and See: A/C Liquid Line - Removal. 19. Remove the rear section of the A/C liquid line from the engine compartment. Rear REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: The A/C liquid line is serviced in two sections. The front section connects between the A/C condenser and the receiver/drier. The rear section connects between the receiver/drier and the front A/C expansion valve. On models equipped with the rear heating-A/C system, the rear section of the A/C liquid line also includes an extension tube that connects the liquid line to the underbody lines. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1643 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 4. Disconnect the A/C liquid line (1) from the receiver/drier and the front A/C expansion valve See: A/C Liquid Line - Removal. 5. Remove the secondary retaining clip (7) from the refrigerant line coupler (6) on the liquid line extension tube (8) 6. Disconnect the underbody liquid line from the liquid line extension tube using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent) and remove and discard the O-ring seal See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Removal. 7. Install plugs in, or tape over the refrigerant line coupler and the underbody liquid line. 8. Remove the A/C liquid line from the engine compartment. Front INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: Always use ND-11 Polyester (POE) oil from Mopar(R) in Hybrid Electric Vehicle (HEV) models. Never use Polyalkylene Glycol (PAG) oil in an HEV model. See Refrigerant Oil for more information. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C liquid line is serviced in two sections. The front section connects between the A/C condenser and the receiver/drier. The rear section connects between the receiver/drier and the A/C expansion valve. On models equipped with the rear heating-A/C system, the rear section of the A/C liquid line also includes an extension tube that connects the liquid line to the underbody lines. FRONT SECTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1644 1. Position the front section of the A/C liquid line (2) into the engine compartment. 2. Remove the tape or plugs from the liquid line fitting and the condenser port. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the A/C liquid line to the A/C condenser (3). 5. Install the nut (1) that secures the A/C liquid line to the A/C condenser. Tighten the nut to 22 Nm (16 ft. lbs.). 6. Remove the tape or plugs from the liquid line fitting and the receiver/drier (3). 7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the front section of the A/C liquid line (2) to the receiver/drier. 9. Install the bolt (1) that secures the front section of the A/C liquid line to the receiver/drier. Tighten the bolt to 13.5 Nm (120 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1645 10. Install the air cleaner housing and resonator (1) See: Filters/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 11. On HEV models, reconnect the battery system using the service disconnect at the battery pack . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 12. On gasoline only models, connect the negative battery cable. 13. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 14. Adjust the refrigerant oil level See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity. 15. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. REAR SECTION 1. Position the rear section of the A/C liquid line into the engine compartment. 2. Install the A/C suction line (2) into the liquid line tapping block (4). 3. Install the plastic retainer (1) that secures the A/C suction line to the liquid line tapping block. 4. Remove the tape or plugs from the suction and liquid line fittings and the A/C expansion valve (5). 5. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and a new gasket onto the A/C expansion valve. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 6. Connect the A/C suction line and the rear section of the A/C liquid line to the A/C expansion valve. 7. Install the nut (3) that secures the refrigerant line tapping block to the A/C expansion valve. Tighten the nut to 23 Nm (17 ft. lbs.). 8. On models equipped with the rear heating-A/C system, connect the underbody liquid line to the liquid line tapping block See: A/C Liquid Line Installation or See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Installation. 9. Install the right front wheelhouse splash shield. 10. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1646 11. Remove the tape or plugs from the liquid line fitting and the receiver/drier (3). 12. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 13. Connect the rear section of the A/C liquid line (2) to the receiver/drier. 14. Install the bolt (1) that secures the rear section of the A/C liquid line to the receiver/drier. Tighten the bolt to 11 Nm (97 in. lbs.). 15. On Hybrid Electric Vehicle (HEV) models, install the Traction Power Inverter Module (TPIM) (1) and mounting bracket (2) See: Hybrid Drive Systems/Power Control System/Voltage Inverter/Service and Repair/Traction Power Inverter Module - Installation. 16. Install the TPIM coolant recovery bottle See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/TPIM Coolant Recovery Container - Installation. 17. Install the rear section of the liquid line (2) into the plastic retainer (3) located on the right inner fender (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1647 18. Install the air cleaner housing and resonator (1) See: Filters/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 19. On HEV models, reconnect the battery system using the service disconnect at the battery pack . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 20. On gasoline only models, connect the negative battery cable. 21. On HEV models, refill the TPIM cooling system . See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 22. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 23. Adjust the refrigerant oil level See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity. 24. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Rear INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: Always use ND-11 Polyester (POE) oil from Mopar(R) in Hybrid Electric Vehicle (HEV) models. Never use Polyalkylene Glycol (PAG) oil in an HEV model. See Refrigerant Oil for more information. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C liquid line is serviced in two sections. The front section connects between the A/C condenser and the receiver/drier. The rear section connects between the receiver/drier and the front A/C expansion valve. On models equipped with the rear heating-A/C system, the rear section of the A/C liquid line also includes an extension tube that connects the liquid line to the underbody lines. 1. Install the A/C liquid line (1) to the receiver/drier and the front A/C expansion valve See: A/C Liquid Line - Installation 2. Remove the tape or plugs from the refrigerant line coupler (6) and the underbody liquid line. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the refrigerant line coupler. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the underbody liquid line to liquid line extension tube (8) See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1648 5. Install the secondary retaining clip (7) onto the refrigerant line coupler. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 6. On HEV models, reconnect the battery system using the service disconnect at the battery pack . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 7. On gasoline only models, reconnect the negative battery cable. 8. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 9. Adjust the refrigerant oil level See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity. 10. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Front 5.7L ENGINES WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: The A/C suction line on 5.7L engines is serviced in two sections. FRONT SECTION NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 4. Raise and support the vehicle. 5. Remove the nut (3) that secures the A/C suction line (2) to the A/C compressor (5). CAUTION: On HEV models, a small quantity of refrigerant oil may be lost from the A/C compressor when the A/C suction line is disconnected. Prior to removing the A/C suction line from the A/C compressor, it very important to place a small clean container Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1649 below the suction line fitting to capture any refrigerant oil that may leak from the compressor suction port. Always measure the amount of refrigerant oil lost and replace with the same amount of fresh clean ND-11 POE refrigerant oil prior to recharging the A/C system. Never use PAG oil in an HEV model or operate the A/C system with an incorrect amount of oil in the system. Failure to follow this caution may result in serious damage to the HEV A/C system. 6. Disconnect the A/C suction line from the A/C compressor and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over, the opened suction line fitting and the compressor port. 8. On HEV model, disengage the wire harness (1) from the suction line bracket (2) and remove the bolt that secures the bracket to the front of the engine. NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 9. Lower the vehicle. 10. Remove the air cleaner housing and resonator See: Filters/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. 11. Remove the nut (1) that secures the front section of the A/C suction line (4) to the rear section of the A/C suction line (2). 12. On 5.7L gas only model, remove the nut (5) that secures the front section of the A/C suction line to the bracket (3) located at the front of the engine. 13. Remove the front section of the A/C suction line and remove and discard the O-ring seal and gasket. 14. Install plugs in, or tape over, the opened suction line fittings. REAR SECTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1650 NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 4. Remove the air cleaner housing and resonator See: Filters/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. 5. Remove the nut (1) that secures the front section of the A/C suction line (4) to the rear section of the A/C suction line (2). 6. Install plugs in, or tape over, the opened suction line fittings. 7. Raise and support the vehicle. 8. Remove the right front wheelhouse splash shield. 9. Remove the plastic retainer (1) that secures the rear section of the A/C suction line (2) to the liquid line tapping block (4). 10. Remove the nut (3) that secures the liquid line tapping block to the A/C expansion valve (5). 11. Disconnect the A/C suction and liquid lines from the A/C expansion valve and remove and discard the O-ring seals and gaskets. 12. Install plugs in, or tape over, the opened refrigerant line fittings and expansion valve ports. 13. Separate the A/C suction line from the liquid line tapping block. 14. On models equipped with the rear heating-A/C\ system, disconnect the underbody refrigerant line from the A/C suction line\ See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Removal and See: A/C Suction Line - Removal. 15. Remove the rear section of the A/C suction line from the engine compartment. Rear REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1651 WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: The A/C suction line connects between the A/C evaporator and the A/C compressor. On models equipped with the rear heating-A/C system, the A/C suction line also includes an extension tube that connects the suction line to the underbody lines. 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 4. Disconnect the A/C suction line (3) from the A/C compressor and the front A/C expansion valve See: A/C Suction Line - Removal 5. Remove the secondary retaining clip (2) from the refrigerant line coupler (6) on the suction line extension tube (5) 6. Disconnect the underbody suction line from the suction line extension tube using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent) and remove and discard the O-ring seal See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Removal. 7. Install plugs in, or tape over the refrigerant line coupler and the underbody suction line. 8. Remove the A/C suction line from the engine compartment. Front 5.7L ENGINE CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: Always use ND-11 Polyester (POE) oil from Mopar(R) in Hybrid Electric Vehicle (HEV) models. Never use Polyalkylene Glycol (PAG) oil in an HEV model. See Refrigerant Oil for more information. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity . Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1652 NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C suction line on 5.7L engines is serviced in two sections. FRONT SECTION NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 1. Position the front section of the A/C suction line (4) into the engine compartment. 2. Remove the tape or plugs from the open suction line fittings. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the front section of the A/C suction line to the rear section of the A/C suction line (2) and install the retaining nut (1). Tighten the nut to 23 Nm (17 ft. lbs.). 5. On 5.7L gas only model, install the nut (5) that secures the front section of the A/C suction line to the bracket (3) located at the front of the engine. Tighten the nut securely. NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 6. Raise and support the vehicle. 7. Remove the tape or plugs from the open suction line fitting and the compressor port. 8. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 9. Install the A/C suction line (2) onto the A/C compressor (5). 10. Install the nut (3) that secures the A/C suction line to the A/C compressor. Tighten the nut to 23 Nm (17 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1653 11. On HEV model, install the suction line bracket (2) and retaining bolt and engage the wire harness (1) to the bracket. Tighten the bolt securely. 12. Lower the vehicle. 13. Install the air cleaner housing and resonator See: Filters/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 14. On HEV models, reconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 15. On gasoline only models, reconnect the negative battery cable. 16. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. CAUTION: On HEV models, a small quantity of refrigerant oil may have been lost from the A/C compressor when the A/C suction line was disconnected. Always replace the lost oil with the same amount of fresh clean ND-11 POE refrigerant oil prior to recharging the A/C system. Never use PAG oil in an HEV model or operate the A/C system with an incorrect amount of oil in the system. Failure to follow this caution may result in serious damage to the HEV A/C system. 17. Adjust the refrigerant oil level See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity. 18. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. REAR SECTION 1. Position the rear section of the A/C suction line (2) into the engine compartment. 2. Install the A/C suction line into the liquid line tapping block (4). 3. Install the plastic retainer (1) that secures the A/C suction line to the liquid line tapping block. 4. Remove the tape or plugs from the suction and liquid line fittings and the A/C expansion valve (5). 5. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and a new gasket onto the suction and liquid line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 6. Connect the A/C suction line and A/C liquid line to the A/C expansion valve. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1654 7. Install the nut (3) that secures the refrigerant line tapping block to the A/C expansion valve. Tighten the nut to 23 Nm (17 ft. lbs.). 8. On models equipped with the rear heating-A/C system, connect the underbody refrigerant line to the A/C suction lineSee: A/C Suction Line Installation and See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Installation. 9. Install the right front wheelhouse splash shield. NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 10. Lower the vehicle. 11. Remove the tape or plugs from the open suction line fittings. 12. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 13. Connect the front section of the A/C suction line (4) to the rear section of the A/C suction line (2) and install the retaining nut (1). Tighten the nut to 23 Nm (17 ft. lbs.). 14. Install the air cleaner housing and resonatorSee: Filters/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 15. On HEV models, reconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 16. On gasoline only models, reconnect the negative battery cable. 17. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. CAUTION: On HEV models, a small quantity of refrigerant oil may have been lost from the A/C compressor when the A/C suction line was disconnected. Always replace the lost oil with the same amount of fresh clean ND-11 POE refrigerant oil prior to recharging the A/C system. Never use PAG oil in an HEV model or operate the A/C system with an incorrect amount of oil in the system. Failure to follow this caution may result in serious damage to the HEV A/C system. 18. Adjust the refrigerant oil level See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity. 19. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Rear INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: Always use ND-11 Polyester (POE) oil from Mopar(R) in Hybrid Electric Vehicle (HEV) models. Never use Polyalkylene Glycol (PAG) oil in an HEV model. See Refrigerant Oil for more information. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1655 operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C suction line connects between the A/C evaporator and the A/C compressor. On models equipped with the rear heating-A/C system, the A/C suction line also includes an extension tube that connects the suction line to the underbody lines. 1. Install the A/C suction line (3) to the A/C compressor and the front A/C expansion valve See: A/C Suction Line - Installation. 2. Remove the tape or plugs from the refrigerant line coupler (6) and the underbody suction line. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the refrigerant line coupler. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the underbody suction line to the suction line extension tube (5) See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Installation. 5. Install the secondary retaining clip (2) onto the refrigerant line coupler. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 6. On HEV models, reconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 7. On gasoline only models, reconnect the negative battery cable. 8. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 9. Adjust the refrigerant oil level See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity. 10. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. A/C Underbody Lines - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1656 operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 4. Drain the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 5. Raise and support the vehicle. 6. Remove the right front wheelhouse splash shield. 7. Remove the secondary retaining clips (2 and 7) from the refrigerant line couplers (6) located on the suction line extension tube (5) and the liquid line extension tube (8). 8. Disconnect the underbody liquid and suction lines from the liquid line extension tube and the suction line extension tube using the proper A/C line disconnect tools (Special Tool Kit 7193 or equivalent) and remove and discard the O-ring seals See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Refrigerant Line Coupler Removal. 9. Install plugs in, or tape over the refrigerant line couplers and the underbody refrigerant lines. 10. Disconnect the underbody heater hoses from the front heater hoses. 11. Remove the nut (1) that secures the rear suction line (2) and the rear liquid line (3) to the rear evaporator line tapping plate that extends through the rear floor panel (4) behind the right rear wheel housing. 12. Disconnect the rear suction line and liquid line from the rear evaporator line tapping plate and remove and discard the O-ring seals. 13. Install plugs in, or tape over the opened refrigerant lines and tapping plate ports. 14. Disconnect the rear heater hoses (5) from the rear heater core tubes that extend through the rear floor panel behind the right rear wheel housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1657 15. Remove all body mount bolts on the passenger side of the vehicle and loosen the body mount bolts on the drivers side. 16. Place a jackstand at the front and rear of the vehicle on the passenger side so that the stands will safely support the body. 17. Remove the five screws (7) that secure the underbody lines (1) to the vehicle underbody (2). 18. Carefully lower the hoist until the right side of the body (supported by the stands) is approximately 76-101 mm (3-4 in.) above the frame. This will gain access to remove the underbody line assembly. 19. Remove the underbody line assembly from the underneath of the vehicle body. A/C Underbody Lines - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: Always use ND-11 Polyester (POE) oil from Mopar(R) in Hybrid Electric Vehicle (HEV) models. Never use Polyalkylene Glycol (PAG) oil in an HEV model. See Refrigerant Oil for more information. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1658 1. Position the underbody line assembly underneath the vehicle body. 2. Carefully raise the hoist until the frame and body mounts line up together. 3. Install the five screws that secure the underbody lines (1) to the vehicle underbody (2). 4. Install all body mount bolts to the passenger side of the vehicle. Tighten all passenger and driver side mount bolts securely. 5. Raise the hoist and remove the jack stands from under the vehicle. 6. Connect the rear heater hoses (5) to the rear heater core tubes that extend through the rear floor panel (4) behind the right rear wheel housing and install the heater hose clamps. 7. Remove the tape or plugs from fittings on the rear suction line (2) and the rear liquid line (3) and the rear evaporator extension line tapping plate ports. 8. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the rear suction and liquid line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 9. Connect the rear suction and liquid line fittings to the rear evaporator line tapping plate. 10. Install the nut (1) that secures the rear refrigerant lines to the rear evaporator line tapping plate. Tighten the nut to 23 Nm (17 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 1659 11. Connect the underbody heater hoses to the front heater hoses and install the heater hose clamps. 12. Remove the tape or plugs from the refrigerant line couplers (6) and the underbody refrigerant lines. 13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install them onto the refrigerant line couplers. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 14. Connect the underbody liquid and suction lines to the liquid line extension tube (8) and the suction line extension tube (5) See: Heating and Air Conditioning/Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Installation. 15. Install the secondary retaining clips (2 and 7) onto the refrigerant line couplers. 16. Install passenger side tires See: Wheels and Tires/Service and Repair/Removal and Replacement. 17. Install the right front wheelhouse splash shield. 18. Lower the vehicle. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 19. On HEV models, reconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 20. On gasoline only models, reconnect the negative battery cable. 21. Fill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 22. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 23. Adjust the refrigerant oil level See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Oil Capacity. 24. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal Power Steering Line/Hose: Service and Repair Power Steering Hose - Removal Pressure Hose PRESSURE HOSE 1. Siphon the fluid from the power steering pump reservoir (1). 2. Raise and support the vehicle. 3. Remove the left front wheel. 4. Remove the inner fender See: Body and Frame/Fender/Front Fender/Service and Repair/Front Fender - Removal 5. Remove the return hose (5) at the gear to gain access to the pressure hose (4). 6. Remove the pressure hose (4) at the gear. 7. Disconnect the pressure hose from the retainer at the crossmember. 8. Remove the pressure hose (4) at the pump pressure hose extension (6). 9. Remove the pressure hose (4) from the vehicle. Return Hose RETURN HOSE 1. Siphon the fluid from the power steering pump reservoir (1). 2. Raise and support the vehicle. 3. Remove the left front wheel. 4. Remove the inner wheel well See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation 5. Disconnect the return hose from the retainer at the crossmember. 6. Remove the return hose (5) at the gear. 7. Remove the return hose (5) at the reservoir (1). 8. Remove the return hose from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1664 Power Steering Line/Hose: Service and Repair Power Steering Hose - Installation Pressure Hose PRESSURE HOSE 1. Install the pressure hose (4) to the vehicle. 2. Connect the pressure hose (4) at the pump pressure hose extension (6). Tighten the hose to 34 Nm (25 ft. lbs.). 3. Connect the pressure hose (4) at the gear. Tighten the hose to 37 Nm (27 ft. lbs.). 4. Connect the return hose (5) to the gear. Tighten the hose to 37 Nm (27 ft. lbs.). 5. Connect the pressure hose (4) to the retainer clip and the crossmember. 6. Install the inner wheel well See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation. NOTE: Before installing inner wheel well, verify that the hose is not touching other components. 7. Install the wheel and tire See: Wheels and Tires/Service and Repair/Removal and Replacement. 8. Remove the support and lower the vehicle. 9. Refill the power steering system See: Fluids/Power Steering Fluid/Service and Repair. Return Hose RETURN HOSE 1. Install the return hose to the vehicle. 2. Connect the return hose (5) at the reservoir (1). 3. Connect the return hose (5) at the gear. Tighten the hose to 37 Nm (27 ft. lbs.). 4. Connect the return hose (5) to the retainer clip and the crossmember. NOTE: Before installing inner wheel well, verify that the hose is not touching other components. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 1665 5. Install the inner wheel well. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation 6. Install the wheel and tire. See: Wheels and Tires/Service and Repair/Removal and Replacement 7. Remove the support and lower the vehicle. 8. Refill the power steering system See: Fluids/Power Steering Fluid/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1671 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Technical Service Bulletins > Page 1672 Brake Fluid: Specifications Brake Fluid Type Mopar DOT 3 and SAE J1703 should be used. If DOT 3 brake fluid is not available, then DOT 4 is acceptable. Use only recommended brake fluids. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Description and Operation > Brake Fluid - Description Brake Fluid: Description and Operation Brake Fluid - Description BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Description and Operation > Brake Fluid - Description > Page 1675 Brake Fluid: Description and Operation Brake Fluid BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Description and Operation > Page 1676 Brake Fluid: Testing and Inspection BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Description and Operation > Page 1677 Brake Fluid: Service and Repair BRAKE FLUID LEVEL Always clean the master cylinder reservoir (1) and cap (2) before checking fluid level. If not cleaned, dirt could enter the fluid. The fluid fill level is indicated on the side of the master cylinder reservoir (1). The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1682 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1687 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Cooling System Capacity With Rear Heat ................................................................................................................................................... 16.6 qts. (15.8L) Note: Includes 2.1 qts (2L) for coolant bottle. TPIM Cooling System TPIM Coolant System .......................................................................................................................... ............................................................ 2.3 qts (2.2L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1690 Coolant: Fluid Type Specifications Engine Coolant Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Description - HOAT Coolant Coolant: Description and Operation Description - HOAT Coolant HOAT COOLANT WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children. Dispose of glycol based coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps require special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT) may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic. The increased temperature can result in severe engine damage. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Description - HOAT Coolant > Page 1693 Coolant: Description and Operation Operation COOLANT Coolant flows through the engine block and cylinder head, absorbing heat from the engine, then flows to the radiator where the cooling fins in the radiator transfer the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by the mixture ratio of coolant to water. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page 1694 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Check coolant concentration when any additional coolant is added to the system, or after a coolant drain, flush and refill. Use of a hydrometer or Refractometer Tool 8286, refractometer can be used to test coolant concentration. A hydrometer tests the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and the higher the freeze protection (up to a maximum of 60% by volume glycol). A Refractometer Tool 8286 tests the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufacturers use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and are not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1699 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1704 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1709 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Differential Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1714 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1719 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications EVT/ASH-T Transmission Service Fill ........................................................................................................................................... ........................................................ 23.2 pts (11.0L) Overhaul Fill ........................................................................................................................................ ......................................................... 26.4 pts (12.5L) Dry fill capacity, depending on the type and size of the internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler. These figures may vary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1722 Fluid - A/T: Fluid Type Specifications EVT/ASH-T Transmission ................................................................................................................... ................................................................. Dexron VI Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1723 Fluid - A/T: Description and Operation AUTOMATIC TRANSMISSION FLUID NOTE: Refer to Service Procedures for fluid level checking procedures. Dexron VI Automatic Transmission Fluid is the only recommended fluid for the Hybrid transmission. Mopar(R) ATF +4, Automatic Transmission Fluid is the recommended fluid for most Chrysler automatic transmissions. Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid. Mopar(R) ATF +4 as well as Dexron VI Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. FLUID ADDITIVES Chrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various "special" additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of Chrysler and these additives must not be used. The use of transmission "sealers" should also be avoided, since they may adversely affect the integrity of transmission seals. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level Fluid - A/T: Testing and Inspection Effects of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 1726 Fluid - A/T: Testing and Inspection Causes of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and auxiliary cooler. This condition is usually the result of a faulty or improperly installed drain back valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 1727 Fluid - A/T: Testing and Inspection Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid. - failure to clean dipstick and fill tube when checking level. - engine coolant entering the fluid. - internal failure that generates debris. - overheat that generates sludge (fluid breakdown). - failure to replace contaminated damper after repair. The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. Wipe the dipstick cap and fill tube clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. Replace the transmission damper whenever a failure generates sludge and debris. Normal flushing procedures will not remove all contaminants. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check Fluid - A/T: Service and Repair Fluid Level Check FLUID LEVEL CHECK The 2 - Mode EVT transmission uses special Dexron VI oil. Do not use Chrysler MS-9602 oil in the 2 - Mode EVT. A service dipstick, (dipstick 9336A) is required to check the oil level in the 2 - Mode EVT transmission. The fill tube is located on the right side of the engine and is accessed through the right front wheel well. To avoid contaminating the transmission fluid, make sure to clean all dirt and debris from the fill tube cap and around the fill tube opening before removing the fill tube cap. The torque damper fills with fluid in both the P (Park) and N (Neutral)positions. Place the selector lever in P (PARK) to make sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute with the vehicle on level ground. At normal operating temperature the fluid level is correct if it is at the level shown in the table below on the service dipstick. After the fluid has been checked, seat the fill tube cap fully on the fill tube opening to seal out contaminants. CAPPED FILL TUBE WARNING: This vehicle has two modes of operation. Even with the gas engine off, the vehicle is still capable of moving in electric only mode. When the engine is running, there is also the risk of personal injury or property damage from the vehicle unintentionally being placed into a drive gear and moving. Verify the parking brake is operating correctly, and apply the parking brake while checking the transmission fluid level. There is a risk of injury from rotating or hot parts on the engine when it has been run or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly fastened and close-fitting work clothes. Do not touch hot or rotating parts. 1. Verify that the vehicle is parked on a level surface. Apply the parking brake. 2. Turn the key on and connect the scan tool to the data link connector. 3. Remove the fill tube cap. 4. Start the engine and let it run at idle speed in the selector lever position "P" until the engine reaches normal operating temperature. 5. Apply and hold the service brake. Shift the transmission into DRIVE for approximately two seconds with the vehicle stationary and the engine idling. 6. Shift the transmission into REVERSE for approximately two seconds with the vehicle stationary and the engine idling. 7. Shift the transmission into park. 8. Use the scan tool to view the transmission fluid temperature sensor. 9. Compare the transmission fluid temperature shown on the scan tool with the transmission fluid level chart. 10. Adjust the transmission fluid level shown on the dipstick according to the transmission fluid temperature chart. NOTE: After adding fluid to the transmission, wait a minimum of two minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1730 Fluid - A/T: Service and Repair Fluid/Filter Service FLUID AND FILTER REPLACEMENT WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. REMOVAL 1. Raise and support the vehicle. See: Vehicle Lifting/Service and Repair. 2. Disconnect the transmission auxiliary oil pump electrical connector. 3. Remove the bolt (1) securing the auxiliary oil pump harness (2) to the transmission bellhousing (3). 4. Remove the transmission auxiliary oil pump bolts (1) and then remove the pump (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1731 5. Place a suitable container under the transmission pan (1). 6. Remove the drain plug, if equipped. 7. Remove bolts holding front and sides of oil pan to transmission. 8. Loosen bolts holding rear of oil pan to transmission. 9. Slowly separate front of oil pan (1) away from transmission (4), allowing the fluid to drain into the drain pan. 10. Supporting the oil pan, remove remaining bolts securing pan to transmission. 11. While holding the oil pan level, lower it from transmission. 12. Pour any remaining fluid in pan into drain pan. 13. Separate the primary (2) and auxiliary (3) oil filters from valve body and oil pump and pour fluid from the filters into drain pan. 14. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove with a suitable tool, and discard the oil filter seals from the bottom of the oil pump. If the seals are installed correctly and are in good condition, they can be reused. 15. Dispose of used transmission fluid and filter(s) properly. INSPECTION Inspect the bottom of the oil pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the oil pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and oil pan are contaminated with excessive amounts of debris, refer to the diagnosis section. CLEANING 1. Using a suitable solvent, clean the oil pan and magnet. INSTALLATION CAUTION: The primary and auxiliary oil filter seals MUST be fully installed flush against the oil pump body. DO NOT install the seals onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install new primary (2) and auxiliary (2) oil filter seals in the oil pump inlet bore. Seat the seal in the bore with Installer 6960 or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place new primary (2) and auxiliary (3) oil filters in position on valve body and into the oil pump. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1732 3. Position the oil pan (1) on transmission. 4. Install bolts to secure pan to transmission. Tighten the oil pan bolts to 27 Nm (20 ft. lbs.). 5. Install the auxiliary oil pump (2). Install the bolts (1) and tighten to 11 Nm (8 ft. lbs.). 6. Install the bolt (1) securing the auxiliary oil pump harness (2) to the transmission bellhousing (3). Tighten the bolt to 11 Nm (8 ft. lbs.). 7. Connect the auxiliary oil pump electrical connector. 8. Lower the vehicle and remove. 9. Fill the transmission with DEXRON(R) VI. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Procedures/Transmission Fill Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 1733 Fluid - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling the transmission after a fluid change or overhaul, perform the following procedure: 1. Remove the cap on the filler tube and insert a clean funnel in the transmission fill tube. 2. Add following initial quantity of DEXRON(R) VI to the transmission: a. If only fluid and filters are being changed, add 23.2 pints (11.0 liters) of DEXRON(R) VI to transmission. b. If transmission was completely overhauled and the damper was replaced or drained, add 28.5 pints (13.5 liters) of DEXRON(R) VI to the transmission. 3. Check the transmission fluid and adjust as required. . See: Fluid Level Check Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1738 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1743 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1748 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Axle C20F .................................................................................................................................................... .............................................................. 55 oz (1.6 L) Rear Axle 8 1/4 Hybred Electric Vehicle (HEV) .................................................................................................... ............................................................ 64 oz (1.9L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1751 Fluid - Differential: Fluid Type Specifications Front Axle C20F .................................................................................................................................................... ................................. Mopar Gear Lubricant 75W-90 Rear Axle 8 1/4 Hybred Electric Vehicle (HEV) .......................................................................... SAE 75W-90 multipurpose type, GL-5 gear lubricant or equivalent Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1756 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications MP3010 ............................................................................................................................................... ......................................................... 2.85 pts (1.35L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1759 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid ............................................................................................................................. ........................................................... Mopar ATF +4 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 1760 Fluid - Transfer Case: Service and Repair STANDARD PROCEDURE - FLUID DRAIN/REFILL The fill and drain plugs are both in the rear case. 1. Raise vehicle. Ensure that the vehicle is level on the hoist. 2. Position drain pan under transfer case. 3. Remove fill plug (1) and drain plug (2) and drain lubricant completely. 4. Install drain plug (2) and tighten plug to 27 Nm (20 ft. lbs.). 5. Fill transfer case to bottom edge of fill plug opening with MOPAR(R) ATF+4 6. Install and tighten fill plug (1) and tighten plug to 27 Nm (20 ft. lbs.). 7. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1765 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil (with filter) .......................................................................................................................... ............................................................. 6.6L (7.0 Qt) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1768 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................................... SAE 5W-20 API Certified, meeting material standard MS-6395 or equivalent Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1769 Engine Oil: Description and Operation ENGINE OIL WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. When service is required, Chrysler Corporation recommends that only Mopar(R) brand parts, lubricants and chemicals be used. Mopar(R) provides the best engineered products for servicing Chrysler Corporation vehicles. Only lubricants bearing designations defined by the following organization should be used. - Society of Automotive Engineers (SAE) - American Petroleum Institute (API) - National Lubricating Grease Institute (NLGI) - Association des Constructeurs Europeens d' Automobiles (European Automobile Manufacturers Association) (ACEA) API SERVICE GRADE CERTIFIED Use an engine oil that is API Certified. MOPAR(R) provides engine oils, that meet or exceed this requirement. SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation. Refer to the engine oil filler cap for the recommend engine oil viscosity for each vehicle. ACEA Categories For countries that use the ACEA European Oil Categories for Service Fill Oils, use engine oils that meet the requirements of ACEA A1/B1, A2/B2, or A3/B3. ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container. CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the front label of engine oil plastic bottles and the top of engine oil cans. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1770 This symbol means that the oil has been certified by the American Petroleum Institute (API). DaimlerChrysler only recommend API Certified engine oils. Use Mopar(R) engine oil or equivalent. SYNTHETIC ENGINE OILS There are a number of engine oils being promoted as either synthetic or semi-synthetic. If you chose to use such a product, use only those oils that meet the American Petroleum Institute (API) and SAE viscosity standard. Follow the service schedule that describes your driving type. ENGINE OIL ADDITIVES/SUPPLEMENTS The manufacturer does not recommend the addition of any engine oil additives/supplements to the specified engine oil. Engine oil additives/supplements should not be used to enhance engine oil performance. Engine oil additives/supplements should not be used to extend engine oil change intervals. No additive is known to be safe for engine durability and can degrade emission components. Additives can contain undesirable materials that harm the long term durability of engines by: - Doubling the level of phosphorus in the engine oil. The ILSAC (International Lubricant Standard Approval Committee) GF-2 and GF-3 standards require that engine oil contain no more than 0.10% phosphorus to protect the vehicles emissions performance. Addition of engine oil additives/supplements can poison, from the added sulfur and phosphorus, catalysts and hinder efforts to guarantee emissions performance to 80,000 miles. - Altering the viscosity characteristics of the engine oil so that it no longer meets the requirements of the specified viscosity grade. - Creating potential for an undesirable additive compatibility interaction in the engine crankcase. Generally it is not desirable to mix additive packages from different suppliers in the crankcase; there have been reports of low temperature engine failures caused by additive package incompatibility with such mixtures. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1771 Engine Oil: Service and Repair ENGINE OIL SERVICE The engine oil level indicator is located at the left hand of the engine on the 5.7L engines. CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result. Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about ten minutes before checking oil level. Checking engine oil level on a cold engine is not accurate. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately five minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the ADD mark on dipstick. ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance SchedulesSee: . Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged. 6. Install drain plug in crankcase. Torque to 34 Nm ( 25 ft. lbs.). 7. Lower vehicle and fill crankcase with specified type and amount of engine oil described. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. NOTE: Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING at beginning of this section. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 1776 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1777 Power Steering Fluid: Specifications Power Steering Reservoir Belt Driven Pump ......................... Mopar Power Steering +4, or Mopar ATF +4 Automatic Transmission Fluid is required in the power steering system. Electric Power Steering (EPS) ................................................................................................................. Mopar hydraulic fluid, part number 05127381AA Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1778 Power Steering Fluid: Description and Operation POWER STEERING FLUID There are two types of power steering systems used on this vehicle. The conventional belt driven power steering pump system as well as an Electric Power Steering (EPS) pump system. The EPS pump is used on the 5.7L Hybrid Electric Vehicle (HEV) while the conventional system is used on all other vehicles. BELT DRIVEN PUMP (CONVENTIONAL) Mopar(R) ATF +4, Automatic Transmission Fluid is required in the power steering system. Substitute fluids can induce power steering system failure.Mopar(R) ATF +4, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. EPS PUMP (5.7L HEV) The power steering system is filled at the factory with Pentosan CHF 11S. If necessary, use Mopar(R) hydraulic fluid, part number 05127381AA. Steering noise and reduced component life may result if an unapproved fluid is used. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1779 Power Steering Fluid: Service and Repair POWER STEERING FLUID LEVEL CHECKING - 5.7L (HEV) WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: MOPAR(R) Pentosan CHF 11S MOPAR(R) part # 05127381AA is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. The power steering fluid level can be viewed on the dipstick attached to the filler cap. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21° C to 27°C (70°F to 80°F), the fluid level should read between the minimum and maximum area of the dipstick. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications REFRIGERANT CHARGE CAPACITY REFRIGERANT CHARGE CAPACITY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1784 Refrigerant: Fluid Type Specifications Fluid type.............................................................................................................................................. .........................................................................R-134a Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > A/C Refrigerant Refrigerant: Description and Operation A/C Refrigerant A/C REFRIGERANT The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone depleting chlorine. R-134a refrigerant is a nontoxic, nonflammable, clear and colorless liquefied gas. CAUTION: R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure. The A/C refrigerant system is filled-for-life at the factory and requires no regular maintenance. Although not required at specific intervals, the charge level should be checked if system performance deteriorates or if a noise or leak is suspected See: Heating and Air Conditioning/Testing and Inspection/Component Tests and General Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > A/C Refrigerant > Page 1787 Refrigerant: Description and Operation Refrigerant - Description DESCRIPTION The refrigerant used in this A/C system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Description and Operation > A/C Refrigerant > Page 1788 Refrigerant: Description and Operation Refrigerant - Operation OPERATION R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery Refrigerant: Service and Repair Refrigerant System - Recovery REFRIGERANT SYSTEM RECOVERY WARNING: Review safety precautions and warnings before performing this procedure See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: If equipped with the rear heating-A/C system, use a heat gun to warm the underbody refrigerant lines to help remove any trapped refrigerant from the rear A/C system. When servicing the A/C system, an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 must be used (1). Per SAE standard J2788, refrigerant recovery stations must recover 95% of the refrigerant system within 30 minutes at 21.1° C (70° F) and be able to measure the amount of refrigerant removed from the system to an accuracy of 28 grams (1 oz.). See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 1791 Refrigerant: Service and Repair Refrigerant System - Evacuate REFRIGERANT SYSTEM EVACUATE NOTE: Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. If a compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be used. This will eliminate the possibility of contaminating the refrigerant system. If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system: NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. Recover the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 2. Connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment See: Heating and Air Conditioning/Service and Repair/Refrigerant System Recovery. 3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads -88 kPa (-26 in. Hg) vacuum or greater for 30 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes. 4. Close all valves. Turn off and disconnect the vacuum pump. 5. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 1792 Refrigerant: Service and Repair Refrigerant System - Charge REFRIGERANT SYSTEM CHARGE WARNING: Review safety precautions and warnings before performing this procedure See: Heating and Air Conditioning/Service Precautions/Warning and See: Heating and Air Conditioning/Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. NOTE: A/C system refrigerant capacity can be found on the HVAC Specification Label, located in the engine compartment. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Use an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 when charging the A/C system. Per SAE standard J2788, refrigerant recovery stations must charge the system to an accuracy of 14 grams (0.5 oz.). See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. See the equipment manufacturer instructions for more information. NOTE: The Underhood HVAC Specification Label contains the refrigerant fill capacity of the vehicle being serviced. 1. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 2. Connect a manifold gauge set or an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 to the refrigerant system. 3. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station See: Heating and Air Conditioning/Specifications/Capacity Specifications/Refrigerant Charge Capacity. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 4. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 5. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 6. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is operating and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). If the A/C compressor does not operate, test the compressor control circuits and repair as required. 7. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. WARNING: Take care not to open the discharge (high pressure) valve at this time. Failure to follow this warning could result in possible serious or fatal injury. 8. Disconnect the charging station and manifold gauge set from the refrigerant system service ports. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 1793 9. Reinstall the caps onto the refrigerant system service ports. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITY When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The A/C receiver/drier, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. CAUTION: ND-11 Polyester (POE) oil is used in the Denso ES34 A/C compressor found on HEV models. Never use PAG oil in an HEV model or operate the A/C system with an incorrect amount of oil in the system. Failure to follow this caution may result in serious damage to the HEV A/C system. CAUTION: ND-8 PAG oil is used in the Denso 10SR17 and 10SRE20 A/C compressors found on gasoline engine models. Only refrigerant oil of the same type should be used to service these A/C systems. Do not use any other refrigerant oil. Failure to follow this caution may result in serious damage to the A/C system. CAUTION: A/C refrigerant oil containers should be kept tightly capped until ready for use and then tightly capped after use to prevent contamination from moisture and dirt. Refrigerant oil quickly absorbs moisture it comes in contact with, therefore, special effort must be used to keep all A/C system components moisture-free. Moisture in refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. Refer to the reclaim/recycling equipment manufacturers instructions. It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when an A/C condenser, A/C receiver/drier or A/C evaporator is replaced (see Refrigerant Oil Capacities chart). The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation (see Compressor Oil Drain Procedure). REFRIGERANT OIL CAPACITIES COMPRESSOR OIL DRAIN PROCEDURE CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Failure to properly drain and measure the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1798 The A/C compressor is filled with refrigerant oil from the factory. Use the following procedure to drain and measure refrigerant oil from the A/C compressor. 1. Drain all of the refrigerant oil from the original A/C compressor in the vehicle into a clean measured container. 2. Drain all of the refrigerant oil from the new A/C compressor into a clean measured container. CAUTION: Use only clean refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Refill the new A/C compressor with the same amount and type of refrigerant oil that was drained out of the original compressor. 4. Install the new A/C compressor onto the engine See: Heating and Air Conditioning/Compressor HVAC/Service and Repair/A/C Compressor Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1799 Refrigerant Oil: Fluid Type Specifications Gas Type...................................................................................................................................................... ..................................................................ND-8 PAG HEV Type...................................................................................................................................................... .................................................................ND-11 POE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Refrigerant Oil - Description Refrigerant Oil: Description and Operation Refrigerant Oil - Description Gas Models GAS MODELS The refrigerant oil used in the R-134a refrigerant system on models equipped with 3.7L, 4.7L and 5.7L gasoline engine, is a synthetic-based, polyalkylene glycol (PAG), wax free lubricant. Mineral based R-12 refrigerant oils are not compatible with PAG oils and should never be introduced to an R-134a refrigerant system. There are different PAG oils available. Each PAG oil contains a different additive package. A/C compressors in 3.7L, 4.7L and 5.7L gas engine models are designed to use ND-8 refrigerant oil. Use only this type of refrigerant oil. HEV Models HEV MODELS CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. The refrigerant oil used in the R-134a refrigerant system on HEV models is a synthetic Polyester (POE) oil. Never use mineral based R-12 refrigerant oils or synthetic based PAG oils in HEV refrigerant system. There are different POE oil types and grades. Always use ND-11 POE refrigerant oil 68043289AA from Mopar(R) in an HEV model. Use of an incorrect refrigerant oil may create a compatibility problem and lead to A/C system failure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Description and Operation > Refrigerant Oil - Description > Page 1802 Refrigerant Oil: Description and Operation Refrigerant Oil - Operation OPERATION After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Brake Bleeding Brake Bleeding: Service and Repair Manual Brake Bleeding MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers were overhauled, open all caliper bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose (1) to bleed screw and insert opposite end in glass container (2) partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear (3) Right front (4) Left front. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down, hold the pedal down while closing the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. 5. Before moving the vehicle verify the pedal is firm and not mushy. 6. Top off the brake fluid and install the reservoir cap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Brake Bleeding > Page 1807 Brake Bleeding: Service and Repair Pressure Brake Bleeding PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Brake Bleeding > Page 1808 Brake Bleeding: Service and Repair Antilock Brake System Bleeding ABS BRAKE BLEEDING ABS system bleeding requires conventional bleeding methods plus use of the scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. See: OR See: . 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. See: . 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations > Page 1813 Circuit Breaker: Diagrams Connector - 2 WAY CIRCUIT BREAKER - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel Fuse: Locations Fuse Panel FUSE PANELS WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions CAUTION: When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it suggests a problem in the circuit that must be corrected. NOTE: If leaving the vehicle dormant for longer than 21 days you may want to take steps to protect the battery. To do this disconnect the battery or disconnect the two Ignition Off Draw (IOD) fuses located in the auxiliary Power Distribution Center (PDC) in the engine compartment. The IOD cavities include a snap in retainer that allows the fuses to be disconnected without removing them from the fuse block. To reconnect the IOD fuses press them back into the cavity. Underhood Fuses Integrated Power Module (IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel > Page 1818 IPM MODULE An Integrated Power Module (IPM) is located in the left side of the engine compartment. This center contains cartridge fuses, mini fuses and relays. A description of each fuse and component may be stamped on the inside cover, otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart. Integrated Power Module (IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel > Page 1819 HEV Power Distribution Center (PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel > Page 1820 The vehicle is equipped with an electrical Power Distribution Center (PDC) located in the left side of the engine compartment. This center contains cartridge fuses, mini fuses and relays. A description of each fuse and component may be stamped on the inside cover, otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart. These fuses and relays can be obtained from your authorized dealer. HEV Power Distribution Center (PDC) - RELAYS HEV Power Distribution Center (PDC) - FUSES Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel > Page 1821 HEV Power Distribution Center 2 (PDC2) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel > Page 1822 HEV Power Distribution Center 2 (PDC2) Non-HEV Power Distribution Center (PDC) RELAYS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel > Page 1823 FUSES Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel > Page 1824 Interior Fuses Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel > Page 1825 Junction Block Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel > Page 1826 Fuse Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel > Page 1827 The fuse block contains blade-type mini-fuses, relays, and circuit breakers for high-current circuits. It is located in the left kick panel. It is accessible through a snap-in cover. Fuse Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel > Page 1828 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel > Page 1829 Fuse: Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel > Page 1830 Fuse: Locations Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel > Page 1831 Fuse: Locations Junction Block Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Fuse Panel > Page 1832 Fuse: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Hev Power Distribution Center (PDC) Fuse: Application and ID Hev Power Distribution Center (PDC) HEV Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 1835 Fuse: Application and ID Integrated Power Module Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 1836 Fuse: Application and ID Junction Block Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 1837 Fuse: Application and ID Power Distribution Center Power Distribution Center W/O HEV Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Description and Operation > IOD Fuse - Description Fuse: Description and Operation IOD Fuse - Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Integrated Power Module when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the Integrated Power Module as part of the preparation procedures performed just prior to new vehicle delivery. The following circuits are protected by the IOD fuse: - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps - Radio - Underhood Lamp Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Description and Operation > IOD Fuse - Description > Page 1840 Fuse: Description and Operation IOD Fuse - Operation OPERATION The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed. The IOD fuse is disconnected from Integrated Power Module when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Junction Block Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1845 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1846 Fuse Block: Connector Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1847 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1848 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Component Locations > Page 1849 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1852 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1853 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1854 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1855 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1856 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1857 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1858 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1859 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1860 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1861 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1862 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1863 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1864 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1865 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1866 Fuse Block: Connector Views Junction Block C1 (Headlamp And Dash) Connector C1 - (HEADLAMP AND DASH) JUNCTION BLOCK - (HEADLAMP AND DASH) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1867 Junction Block C2 (Instrument Panel Side) Connector C2 - (INSTRUMENT PANEL SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1868 JUNCTION BLOCK - (INSTRUMENT PANEL SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1869 Junction Block C3 (Body Side) Connector C3 - (BODY SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1870 JUNCTION BLOCK - (BODY SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1871 Junction Block C4 (Instrument Panel Side) Connector C4 - (INSTRUMENT PANEL SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1872 JUNCTION BLOCK - (INSTRUMENT PANEL SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1873 Junction Block C5 (Headlamp And Dash) Connector C5 - (HEADLAMP AND DASH) JUNCTION BLOCK - (HEADLAMP AND DASH) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1874 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Hev Power Distribution Center (PDC) Fuse Block: Application and ID Hev Power Distribution Center (PDC) HEV Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 1877 Fuse Block: Application and ID Integrated Power Module Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 1878 Fuse Block: Application and ID Junction Block Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 1879 Fuse Block: Application and ID Power Distribution Center Power Distribution Center W/O HEV Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Description and Operation > Power Distribution Center (PDC) - Description Fuse Block: Description and Operation Power Distribution Center (PDC) - Description DESCRIPTION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) is located next to the Power Distribution Center (PDC) (3) in the engine compartment. The HEV PDC (4) works with the Front Control Module (FCM) (1), the Integrated Power Module (IPM) (2) and the PDC (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 1882 Fuse Block: Description and Operation Power Distribution Center (PDC) - Operation OPERATION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) provides the extra power needed for the Hybrid Electric Vehicle (HEV). The HEV PDC provides power to: - Transmission Auxiliary Pump (TPCM) - Electric Vacuum Pump - Electric High Voltage Power Steering (EHPS) - Solid State Relay Electric Vacuum Pump The HEV PDC is serviced as part of the engine compartment body harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 1883 Fuse Block: Description and Operation Junction Block - Description DESCRIPTION An electrical Junction Block (JB) (1) is concealed behind the left outboard end of the instrument panel cover. The JB combines the functions previously provided by a separate fuseblock module and relay center, serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as a fuse layout to help ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 1884 Fuse Block: Description and Operation Junction Block - Operation OPERATION All of the circuits entering and leaving the JB do so through wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal Fuse Block: Service and Repair Power Distribution Center (PDC) - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Depress retaining tabs on the side on the PDC (1). 3. Disconnect electrical harness connectors (2) and remove PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 1887 Fuse Block: Service and Repair Power Distribution Center (PDC) - Installation INSTALLATION 1. Connect electrical harness connectors to Power Distribution Center (PDC). 2. Position PDC and engage into the retaining tabs. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 1888 Fuse Block: Service and Repair Junction Block - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left cowl trim cover. 3. Remove the mounting fasteners (3). 4. Disconnect the electrical harness connectors and remove Junction Block (1). 5. Transfer components as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 1889 Fuse Block: Service and Repair Junction Block - Installation INSTALLATION 1. Connect wire harness connectors to the Junction Block (JB) (1). 2. Position JB and install mounting fasteners (3). 3. Install left cowl trim cover). 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) Relay Box: Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 1897 Relay Box: Locations Remote Run Relay Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 1898 Relay Box: Locations Run/Start Relay Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 1899 Relay Box: Locations Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 1900 Relay Box: Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Remote Run Relay Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 1901 Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Run/Start Relay Run Remote Relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 1902 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Junction Block Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay-Run Remote Relay Box: Diagrams Relay-Run Remote Connector (IN PDC) RELAY-RUN REMOTE (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Relay-Run Remote > Page 1905 Relay Box: Diagrams Relay-Run/Start Connector (IN PDC) RELAY-RUN/START (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) Relay Box: Application and ID Hev Power Distribution Center (PDC) HEV Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 1908 Relay Box: Application and ID Integrated Power Module Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 1909 Relay Box: Application and ID Junction Block Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 1910 Relay Box: Application and ID Power Distribution Center Power Distribution Center W/O HEV Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description Relay Box: Description and Operation Power Distribution Center (PDC) - Description DESCRIPTION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) is located next to the Power Distribution Center (PDC) (3) in the engine compartment. The HEV PDC (4) works with the Front Control Module (FCM) (1), the Integrated Power Module (IPM) (2) and the PDC (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 1913 Relay Box: Description and Operation Power Distribution Center (PDC) - Operation OPERATION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) provides the extra power needed for the Hybrid Electric Vehicle (HEV). The HEV PDC provides power to: - Transmission Auxiliary Pump (TPCM) - Electric Vacuum Pump - Electric High Voltage Power Steering (EHPS) - Solid State Relay Electric Vacuum Pump The HEV PDC is serviced as part of the engine compartment body harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 1914 Relay Box: Description and Operation Junction Block - Description DESCRIPTION An electrical Junction Block (JB) (1) is concealed behind the left outboard end of the instrument panel cover. The JB combines the functions previously provided by a separate fuseblock module and relay center, serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as a fuse layout to help ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 1915 Relay Box: Description and Operation Junction Block - Operation OPERATION All of the circuits entering and leaving the JB do so through wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal Relay Box: Service and Repair Power Distribution Center (PDC) - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Depress retaining tabs on the side on the PDC (1). 3. Disconnect electrical harness connectors (2) and remove PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 1918 Relay Box: Service and Repair Power Distribution Center (PDC) - Installation INSTALLATION 1. Connect electrical harness connectors to Power Distribution Center (PDC). 2. Position PDC and engage into the retaining tabs. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 1919 Relay Box: Service and Repair Junction Block - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left cowl trim cover. 3. Remove the mounting fasteners (3). 4. Disconnect the electrical harness connectors and remove Junction Block (1). 5. Transfer components as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 1920 Relay Box: Service and Repair Junction Block - Installation INSTALLATION 1. Connect wire harness connectors to the Junction Block (JB) (1). 2. Position JB and install mounting fasteners (3). 3. Install left cowl trim cover. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Indicator - Description Low Tire Pressure Indicator: Description and Operation Low Tire Pressure Indicator - Description DESCRIPTION A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the speedometer dial face to the left of the speedometer needle hub in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Indicator - Description > Page 1926 Low Tire Pressure Indicator: Description and Operation Low Tire Pressure Indicator - Operation OPERATION The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM), over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position, the SKREEM sends an electronic TPM indicator lamp-on message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Indicator Lamp-On Message - Each time the cluster receives an electronic TPM indicator lamp-on message from the SKREEM, the TPM indicator illuminates. The indicator can be flashed on and off, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a lamp-off message from the SKREEM or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-on or lamp-off messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-on or lamp-off message is received from the SKREEM. - Self Test - Each time the cluster is put through the self test, the TPM indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the ON position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or low. The SKREEM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the instrument cluster turns on the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is ineffective. Use a diagnostic scan tool for proper diagnosis of the TPM system, the SKREEM, the CCN, the CAN data bus or the electronic communication related to TPM indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Oil Change Indicator - Description Maintenance Required Lamp/Indicator: Description and Operation Oil Change Indicator Description DESCRIPTION A change oil indicator is standard equipment on all instrument clusters. However, on vehicles manufactured for export markets, this indicator is electronically disabled. This indicator is located within the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. However, on vehicles equipped with the optional Electronic Vehicle Information Center (EVIC), the change oil indicator in the odometer VFD is electronically suppressed so as not to duplicate indications that are provided by the EVIC. The change oil indicator consists of cycling textual CHAngE and OIL messages which appear in place of the odometer/trip odometer information in the odometer VFD unit. The odometer VFD is soldered onto the cluster electronic circuit board, and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The change oil textual messages appear in the same blue-green color and at the same lighting level as the odometer information when they are illuminated by the instrument cluster electronic circuit board. The change oil indicator is serviced as a unit with the VFD in the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Oil Change Indicator - Description > Page 1931 Maintenance Required Lamp/Indicator: Description and Operation Oil Change Indicator - Operation OPERATION The change oil indicator gives an indication to the vehicle operator when a duty-cycle algorithm contained within the software of the Powertrain Control Module (PCM) determines that a recommended oil change interval has been attained. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the PCM. The change oil indicator function of the Vacuum Fluorescent Display (VFD) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the VFD change oil indication is always off when the ignition switch is in any position except ON or START. The instrument cluster turns on the change oil indicator for the following reasons: - Change Oil Indicator Lamp-On Message - Each time the ignition switch is turned to the ON position and the cluster receives an electronic change oil indicator lamp-on message from the PCM indicating that a duty-cycle based recommended oil change interval has been attained, the change oil indicator illuminates for about three seconds, until the trip odometer reset switch button is depressed, or until the ignition switch is turned to the OFF position, whichever occurs first. - Change Oil Indicator Reset Procedure - Once an engine oil change has been completed, the PCM duty cycle counters can be reset using the following procedure. Turn the ignition switch to the on position, butDo not start the engine. Slowly depress and release the accelerator pedal fully three times within ten seconds. Turn the ignition switch to the off position. If the change oil indicator illuminates the next time the engine is started, repeat this procedure. The PCM continually monitors numerous sensor inputs to determine the duty-cycles to which the engine is being subjected. A pre-programmed algorithm within the PCM then determines when to send the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). Use a diagnostic scan tool for proper diagnosis of the change oil indicator, the PCM, the CCN, the CAN data bus or the electronic communication related to change oil indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Malfunction Indicator Lamp - Description Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp - Description DESCRIPTION A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located in the center of the speedometer, in the area to the left of the speedometer needle hub. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Malfunction Indicator Lamp - Description > Page 1936 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp - Operation OPERATION The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM over the Controller Area Network (CAN) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the MIL for the following reasons: - Bulb Test - Each time the ignition switch turns to the on position the indicator is illuminated for about 15 seconds as a bulb test. The entire bulb test is a function of the PCM. - MIL Lamp-On Message - Each time the cluster receives an electronic MIL lamp-on message from the PCM, the indicator illuminates. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM message. For some DTCs, if a problem does not recur, the PCM sends a lamp-off message automatically. Other DTCs may require that a fault be repaired and the PCM be reset before a lamp-off message is sent. For more information on the PCM, and the DTC set and reset parameters, See: Powertrain Management/Emission Control Systems/Testing and Inspection. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the PCM for 10 consecutive message cycles, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM. - Self Test - Each time the cluster is put through the self test, the MIL indicator turns on during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the MIL or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. If the CCN turns on the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. Use a diagnostic scan tool for proper diagnosis of the fuel and emissions systems, the PCM, the CCN, the CAN data bus or the electronic communication related to MIL operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp - Hybrid Drive > Component Information > Description and Operation > Hybrid Service Indicator - Description Malfunction Indicator Lamp - Hybrid Drive: Description and Operation Hybrid Service Indicator Description DESCRIPTION A Hybrid Electric Vehicle (HEV) service indicator is only found in the instrument clusters of vehicles equipped with the optional hybrid system. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The HEV service indicator consists of a stencil-like cutout of the combined International Control and Display Symbol icon for Service, call for maintenance and a lightning bolt icon for Electricity in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The HEV service indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp - Hybrid Drive > Component Information > Description and Operation > Hybrid Service Indicator - Description > Page 1941 Malfunction Indicator Lamp - Hybrid Drive: Description and Operation Hybrid Service Indicator Operation OPERATION The Hybrid Electric Vehicle (HEV) service indicator gives an indication to the vehicle operator when the Hybrid Control Processor (HCP) integral to the Traction Power Inverter Module (TPIM) has recorded a Diagnostic Trouble Code (DTC) for a hybrid systems-related circuit or component malfunction. The HEV service indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the HCP over the Controller Area Network (CAN) data bus. The HEV service indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the HEV service indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the HCP. - HEV Service Lamp-On Message - Each time the cluster receives an electronic HEV service lamp-on message from the HCP, the indicator illuminates. For some DTCs, if a problem does not recur, the HCP sends a lamp-off message automatically. Other DTCs may require that a fault be repaired and the HCP be reset before a lamp-off message is sent. - Self Test - Each time the cluster is put through the self test, the HEV service indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The HCP continually monitors the HEV system circuits, sensors and components to decide whether the system is in good operating condition. The HCP then sends the proper lamp-on or lamp-off message to the instrument cluster also known as the Cab Compartment Node (CCN). For further diagnosis of the HEV service indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. If the CCN turns on the HEV service indicator after the bulb test, it may indicate that a malfunction has occurred and that the HEV system may require service. Use a diagnostic scan tool for proper diagnosis of the HEV system, the HCP, the CCN, the CAN data bus or the electronic communication related to HEV service indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp - Hybrid Drive > Component Information > Description and Operation > Hybrid Service Indicator - Description > Page 1942 Malfunction Indicator Lamp - Hybrid Drive: Description and Operation Regenerative Brake Indicator - Description DESCRIPTION A Regenerative Brake System (RBS) indicator is only found in the instrument clusters of vehicles equipped with the optional Hybrid Electrical Vehicle (HEV) system. This indicator is located below the minor gauge set on the left side of the cluster. The RBS indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Failure of Anti-lock Braking System in the opaque layer of the instrument cluster overlay, but with the letter R replacing the letter A in the ABS acronym. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The RBS indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp - Hybrid Drive > Component Information > Description and Operation > Hybrid Service Indicator - Description > Page 1943 Malfunction Indicator Lamp - Hybrid Drive: Description and Operation Regenerative Brake Indicator - Operation OPERATION The Regenerative Brake System (RBS) indicator gives an indication to the vehicle operator when the RBS system, or a circuit or component of the system is ineffective. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Regenerative Brake Controller (RBC) (also known as the Controller Antilock Brake/CAB) over the Controller Area Network (CAN) data bus. The RBS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the RBS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turns to the on position the RBS indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the RBC. - RBS Indicator Lamp-On Message - Each time the cluster receives an electronic RBS indicator lamp-on message from the RBC, the RBS indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the RBC, or until the ignition switch turns to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the RBC for five consecutive message cycles, the RBS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the RBC, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the instrument cluster is put through the self test, the RBS indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - RBS Diagnostic Test - The RBS indicator is blinked on and off by lamp-on and lamp-off messages from the RBC during the performance of the RBS diagnostic tests. The RBC continually monitors the RBS circuits and sensors to decide whether the system is in good operating condition. The RBC then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the RBC sends a lamp-on message after the bulb test, it indicates that the RBC has detected a system malfunction or that the RBS system has become ineffective. The RBC stores a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the RBS indicator fails to light due to an open or short in the cluster RBS indicator circuit, the cluster sends a message notifying the RBC of the condition, then the instrument cluster and the RBC will each store a DTC. Use a diagnostic scan tool for proper diagnosis of the regenerative brake system, the RBC, the CCN, the CAN data bus or the electronic communication related to RBS indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup Oil Change Reminder Lamp: Technical Service Bulletins Instruments - Vehicle Information Center Setup NUMBER: 08-002-09 GROUP: Electrical DATE: February 4, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-014-07, DATED JULY 11, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL YEARS AND MODELS. SUBJECT: Electronic Vehicle Information Center (EVIC) Oil Change Indicator System - Dealer Preferences During Prep MODELS: 2008 (DR) Ram Truck **2009 (HB) Durango** **2009 (HG) Aspen** **2009 (JC) Journey** **2008 - 2009 (KA) Nitro** **2008 - 2009 (KK) Liberty** **2009 (LC) Challenger** **2008 - 2009 (LX) 300 / Magnum / Charger** **2008 - 2009 (RI) Caravan / Town & Country** NOTE: This Bulletin applies to vehicles equipped with a programmable EVIC. DISCUSSION: **Many models now include an oil change indicator system**. This system displays an "Oil Change Required" or "Oil Change" message at appropriate intervals on the instrument cluster. The vehicles listed above may be equipped with a programmable display on the Electronic Vehicle Information Center, (EVIC). The "Oil Change Required message may also include the dealerships name and phone number which can be programmed into the vehicle with the StarSCAN(R) or StarMOBILE(R) scan tool. NOTE: **Other vehicles may be added at any time. Dealers can determine if the feature is available by following the procedures below. If Enable/Disable Dealer Contact Information is active, the feature can be used to enter the servicing dealer's information.** The following procedure describes the steps to add, delete or change a dealership name and phone number on the display. NOTE: If NOT programmed during vehicle prep, customer approval MUST be obtained before adding or changing this information. NOTE: When performing this Procedure, the software release level in the StarSCAN(R) or StarMOBILE(R); must be programmed with the latest level software. The software release level is visible in the blue header at the top of the StarSCAN(R) or StarMOBILE(R) screen. 1. Connect the StarSCAN(R) or StarMOBILE(R). (in Pass-Through Mode) NOTE: To use the StarMOBILE(R) in Pass-Through Mode requires that StarMOBILE(R) be connected to the dealership network via a wired or wireless connection. For more information on how to use the StarMOBILE(R) in Pass-Through Mode, see the StarMOBILE(R) training tutorials available on DealerCONNECT > Service > Repair > StarSCAN(R) and StarMOBILE(R) Tools link or at the website. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup > Page 1948 2. From the Home Screen, enter "ECU VIEW or "VEHICLE PREP". 3. Select "CCN". 4. Select "Misc. Functions". 5. Select "Enable/Disable Dealer Contact Information". 6. Select "Enable" or "Disable" as desired. 7. If enabled, select "Program Dealer Contact Information" and follow on screen prompts. 8. "Reset will cause display to read: "Contact Dealer" as default. 9. Select finish to exit. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Page 1949 Oil Change Reminder Lamp: Service and Repair Evic Equipped Vehicles Your vehicle is equipped with an engine oil change indicator system. The Oil Change Required message will flash in the EVIC display for approximately 10 seconds after a single chime has sounded to indicate the next scheduled oil change interval. The engine oil change indicator system is duty cycle based, which means the engine oil change interval may fluctuate dependent upon your personal driving style. Unless reset, this message will continue to display each time you turn the ignition switch to the ON/RUN position. To turn off the message temporarily, press and release the Menu button. To reset the oil change indicator system (after performing the scheduled maintenance) perform the following procedure: - Turn the ignition switch to the ON position (Do not start the engine). - Fully depress the accelerator pedal slowly three times within 10 seconds. - Turn the ignition switch to the OFF/LOCK position. NOTE: If the indicator message illuminates when you start the vehicle, the oil change indicator system did not reset. If necessary repeat this procedure. Non-Evic Equipped Vehicles Your vehicle is equipped with an engine oil change indicator system. The Change Oil message will flash in the instrument cluster odometer for approximately 12 seconds after a single chime has sounded to indicate the next scheduled oil change interval. The engine oil change indicator system is duty cycle based, which means the engine oil change interval may fluctuate dependent upon your personal driving style. Unless reset, this message will continue to display each time you turn the ignition switch to the ON/RUN position. To turn off the message temporarily, press and release the Trip Odometer button on the instrument cluster. To reset the oil change indicator system (after performing the scheduled maintenance) perform the following procedure: - Turn the ignition switch to the ON position (Do not start the engine). - Fully depress the accelerator pedal slowly three times within 10 seconds. - Turn the ignition switch to the OFF/LOCK position. NOTE: If the indicator message illuminates when you start the vehicle, the oil change indicator system did not reset. If necessary repeat this procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair HOISTING AND JACKING WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When a chassis or drivetrain component is removed from a vehicle, the center of gravity is altered making some hoisting conditions unstable. Properly support or secure vehicle to hoisting device when these conditions exist. FLOOR JACKING Correct Vehicle Lifting Locations - Typical CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: an axle tube. - aluminum differential. - a body side sill. - a steering linkage component. - a drive shaft. - the engine or transmission oil pan. - the fuel tank. - a front suspension arm. When properly positioned, a floor jack can be used to lift a Durango vehicle. Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. HOISTING A vehicle can be lifted with: - a single-post, frame contact hoist. - a twin-post, chassis hoist. - a ramp-type, drive on hoist. NOTE: When a frame contact type hoist is used, verify that the lifting pads are positioned properly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 1959 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 1960 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way Tire Pressure Monitor Receiver / Transponder: Diagrams Left Front Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT FRONT - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way > Page 1963 Tire Pressure Monitor Receiver / Transponder: Diagrams Left Rear Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT REAR - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way > Page 1964 Tire Pressure Monitor Receiver / Transponder: Diagrams Right Front Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-RIGHT FRONT - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Description DESCRIPTION PREMIUM SYSTEM A transponder, also known as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of the vehicle to provide the WCM/SKREEM with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description > Page 1967 Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Operation OPERATION NUMBER: PREMIUM SYSTEM On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (Each WCM cycle ends when the vehicle has been shut off for a time period of approximately 15 minutes or longer). Once the WCM has performed this to the three locations that have transponders (left front, right front, and left rear wheel wells), it uses the process-of-elimination theory to know that the fourth sensor ID signal is coming from the left rear tire sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Removal Front FRONT TRANSPONDER 1. Raise and support the vehicle. 2. Remove the wheel well housing cover (2). 3. Remove the mounting nut (1) for the transponder (2). 4. Disconnect the electrical connector and remove the transponder (2) from the vehicle. Rear REAR TRANSPONDER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 1970 1. Raise and support the vehicle. 2. Remove the mounting nut (1) for the transponder (2). 3. Disconnect the electrical connector (3) and remove the transponder (2) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 1971 Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Installation Front FRONT TRANSPONDER 1. Install the transponder (2) to the vehicle and reconnect the electrical connector. 2. Install the mounting nuts (1) for the transponder (2) Tighten to 3 Nm (25 in. lbs.). 3. Install the wheel well housing cover (2). 4. Lower the vehicle. Rear REAR TRANSPONDER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 1972 1. Install the transponder (2) to the vehicle and reconnect the electrical connector (3) and secure the harness to the stud (4). 2. Install the mounting nut (1) for the transponder (2). Tighten to 3 Nm (25 in. lbs.). 3. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The TPMS has been optimized for the original equipment tires and wheels. TPMS pressures have been established for the tire size equipped on your vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, and/or style. After-market wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with a TPMS, as damage to the sensors may result. NOTE: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Any time a sensor is to be reinstalled in a wheel, a new seal, cap and valve core must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION NOTE: On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 or 433 MHz radio frequency. The 315 MHz sensors can be easily identified by a black sensor body, with (an oval insignia) (1). The 433 MHz sensors can be identified by a grey sensor body with an oval insignia. NOTE: If replacing the WCM, the spare tire must be dismounted from its wheel to access and note the spare tire pressure sensor ID. Then follow the programming steps outlined in the diagnostic scan tool for "Learn Spare Tire Sensor ID" under Miscellaneous Functions for the WCM wireless control module menu item as appropriate. In addition, the placard pressure thresholds must be updated in the new WCM. Go to "Update Pressure Thresholds" under Miscellaneous Functions for the WCM wireless control module and follow the procedure. On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a black sensor body, with (an oval insignia) (1) and a grey valve cap (2). The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by a gray sensor body (with an oval insignia) and a black valve cap (2). CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Domestic vehicles, use the 315 MHz TPM sensors with the BLACK sensor body. For Export vehicles, use the 433 MHz TPM sensors with the GREY sensor body. Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct color sensor is being used. A RKE-TPM Analyzer can be used to determine the sensor's frequency without having to dismount the tire. NOTE: If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel. (This could cause sealing and system performance issues). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1979 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (4) - Valve Stem Cap (2) - Valve Stem Core - Valve Stem Nut (3) The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 1980 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit if using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor's operating mode and to diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following modes: - Sleep Mode - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. - Park Mode - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 PSI delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure 30 Block Mode - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to Park Mode using a TPM-RKE Analyzer, the sensor's operating mode will transition from Park Mode to 30 Block Mode once the vehicle is driven over 15mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 8 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to Drive Mode - Drive Mode - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time that the vehicle speed drops below 15mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h). If the vehicle has been stationary for more then 20 minutes, the TPM sensor will change to PARK MODE. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 m.p.h. (24 Km/h)" after a sensor has been replaced, The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The sensor IDs can also be programmed using the TPM-RKE Analyzer Tool. Scan each TPM sensor at each road wheel, and store each Sensor ID in the correct location. (LEFT FRONT, LEFT REAR, RIGHT FRONT, and RIGHT REAR) Connect the TPM-RKE Analyzer Tool to the Scan Tool. Then follow the programming steps outlined in the diagnostic Scan Tool for "Program Tire Pressure Sensor ID w/ TPM Tool" under "MISC" for the "WCM/WIRELESS CONTROL MODULE". Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1983 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1984 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 6 Nm (53 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1985 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the outer and inner tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. 8. Remove the support and lower the vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 1986 b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Indicator - Description Low Tire Pressure Indicator: Description and Operation Low Tire Pressure Indicator - Description DESCRIPTION A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the speedometer dial face to the left of the speedometer needle hub in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Indicator - Description > Page 1992 Low Tire Pressure Indicator: Description and Operation Low Tire Pressure Indicator - Operation OPERATION The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM), over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position, the SKREEM sends an electronic TPM indicator lamp-on message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Indicator Lamp-On Message - Each time the cluster receives an electronic TPM indicator lamp-on message from the SKREEM, the TPM indicator illuminates. The indicator can be flashed on and off, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a lamp-off message from the SKREEM or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-on or lamp-off messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-on or lamp-off message is received from the SKREEM. - Self Test - Each time the cluster is put through the self test, the TPM indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the ON position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or low. The SKREEM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the instrument cluster turns on the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is ineffective. Use a diagnostic scan tool for proper diagnosis of the TPM system, the SKREEM, the CCN, the CAN data bus or the electronic communication related to TPM indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 1997 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 1998 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way Tire Pressure Monitor Receiver / Transponder: Diagrams Left Front Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT FRONT - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way > Page 2001 Tire Pressure Monitor Receiver / Transponder: Diagrams Left Rear Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT REAR - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way > Page 2002 Tire Pressure Monitor Receiver / Transponder: Diagrams Right Front Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-RIGHT FRONT - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Description DESCRIPTION PREMIUM SYSTEM A transponder, also known as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of the vehicle to provide the WCM/SKREEM with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder Description > Page 2005 Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Operation OPERATION NUMBER: PREMIUM SYSTEM On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (Each WCM cycle ends when the vehicle has been shut off for a time period of approximately 15 minutes or longer). Once the WCM has performed this to the three locations that have transponders (left front, right front, and left rear wheel wells), it uses the process-of-elimination theory to know that the fourth sensor ID signal is coming from the left rear tire sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Removal Front FRONT TRANSPONDER 1. Raise and support the vehicle. 2. Remove the wheel well housing cover (2). 3. Remove the mounting nut (1) for the transponder (2). 4. Disconnect the electrical connector and remove the transponder (2) from the vehicle. Rear REAR TRANSPONDER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 2008 1. Raise and support the vehicle. 2. Remove the mounting nut (1) for the transponder (2). 3. Disconnect the electrical connector (3) and remove the transponder (2) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 2009 Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Installation Front FRONT TRANSPONDER 1. Install the transponder (2) to the vehicle and reconnect the electrical connector. 2. Install the mounting nuts (1) for the transponder (2) Tighten to 3 Nm (25 in. lbs.). 3. Install the wheel well housing cover (2). 4. Lower the vehicle. Rear REAR TRANSPONDER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 2010 1. Install the transponder (2) to the vehicle and reconnect the electrical connector (3) and secure the harness to the stud (4). 2. Install the mounting nut (1) for the transponder (2). Tighten to 3 Nm (25 in. lbs.). 3. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The TPMS has been optimized for the original equipment tires and wheels. TPMS pressures have been established for the tire size equipped on your vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, and/or style. After-market wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with a TPMS, as damage to the sensors may result. NOTE: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Any time a sensor is to be reinstalled in a wheel, a new seal, cap and valve core must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION NOTE: On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 or 433 MHz radio frequency. The 315 MHz sensors can be easily identified by a black sensor body, with (an oval insignia) (1). The 433 MHz sensors can be identified by a grey sensor body with an oval insignia. NOTE: If replacing the WCM, the spare tire must be dismounted from its wheel to access and note the spare tire pressure sensor ID. Then follow the programming steps outlined in the diagnostic scan tool for "Learn Spare Tire Sensor ID" under Miscellaneous Functions for the WCM wireless control module menu item as appropriate. In addition, the placard pressure thresholds must be updated in the new WCM. Go to "Update Pressure Thresholds" under Miscellaneous Functions for the WCM wireless control module and follow the procedure. On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a black sensor body, with (an oval insignia) (1) and a grey valve cap (2). The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by a gray sensor body (with an oval insignia) and a black valve cap (2). CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Domestic vehicles, use the 315 MHz TPM sensors with the BLACK sensor body. For Export vehicles, use the 433 MHz TPM sensors with the GREY sensor body. Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct color sensor is being used. A RKE-TPM Analyzer can be used to determine the sensor's frequency without having to dismount the tire. NOTE: If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel. (This could cause sealing and system performance issues). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 2016 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (4) - Valve Stem Cap (2) - Valve Stem Core - Valve Stem Nut (3) The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 2017 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit if using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor's operating mode and to diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following modes: - Sleep Mode - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. - Park Mode - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 PSI delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure 30 Block Mode - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to Park Mode using a TPM-RKE Analyzer, the sensor's operating mode will transition from Park Mode to 30 Block Mode once the vehicle is driven over 15mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 8 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to Drive Mode - Drive Mode - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time that the vehicle speed drops below 15mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h). If the vehicle has been stationary for more then 20 minutes, the TPM sensor will change to PARK MODE. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 m.p.h. (24 Km/h)" after a sensor has been replaced, The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The sensor IDs can also be programmed using the TPM-RKE Analyzer Tool. Scan each TPM sensor at each road wheel, and store each Sensor ID in the correct location. (LEFT FRONT, LEFT REAR, RIGHT FRONT, and RIGHT REAR) Connect the TPM-RKE Analyzer Tool to the Scan Tool. Then follow the programming steps outlined in the diagnostic Scan Tool for "Program Tire Pressure Sensor ID w/ TPM Tool" under "MISC" for the "WCM/WIRELESS CONTROL MODULE". Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 2020 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 2021 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 6 Nm (53 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 2022 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the outer and inner tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. 8. Remove the support and lower the vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 2023 b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tires Tires: Description and Operation Tires TIRES Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe brake applications - High speed driving - Excessive speeds on turns - Striking curbs and other obstacles Radial-ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval See: Service and Repair/Procedures. This will help to achieve a greater tread life. TIRE IDENTIFICATION Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code. Performance tires have a speed rating letter after the aspect ratio number. The speed rating is not always printed on the tire sidewall. These ratings are: - Q up to 99 mph - S up to 112 mph - T up to 118 mph - U up to 124 mph - H up to 130 mph - V up to 149 mph - W (consult the tire manufacturer for the specific speed rating) - Z more than 149 mph (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M AND S or M-S (indicating mud and snow traction) imprinted on the side wall. TIRE CHAINS Tire snow chains may be used on certain models. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 2028 Tires: Description and Operation Radial - Ply Tires RADIAL-PLY TIRES Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance. Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary. A maximum speed of 80 KPH (50 MPH) is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could also cause inaccurate wheel speed signals when the vehicle is equipped with Anti-Lock Brakes. The use of tires from different manufactures on the same vehicle is NOT recommended. The proper tire pressure should be maintained on all four tires. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 2029 Tires: Description and Operation Tire Pressure for High Speeds TIRE PRESSURE FOR HIGH SPEED Refer to the Vehicles Owners Manual package. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 2030 Tires: Description and Operation Tire Inflation Pressures TIRE INFLATION PRESSURES WARNING: Over or under inflated tires can affect vehicle handling and tread wear. This may cause the tire to fail suddenly, resulting in loss of vehicle control. Under inflation will cause rapid shoulder wear (1), tire flexing, and possible tire failure. Over inflation will cause rapid center wear (1) reduction in the tire's ability to cushion shocks. Improper inflation can cause: - Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - Vehicle drift For proper tire pressure specification refer to the tire label placard usually located on the drivers door latch pillar. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 2031 Tires: Description and Operation Tires TIRES Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe brake applications - High speed driving - Excessive speeds on turns - Striking curbs and other obstacles Radial-ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval See: Service and Repair/Procedures. This will help to achieve a greater tread life. TIRE IDENTIFICATION Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code. Performance tires have a speed rating letter after the aspect ratio number. The speed rating is not always printed on the tire sidewall. These ratings are: - Q up to 99 mph S up to 112 mph T up to 118 mph - U up to 124 mph - H up to 130 mph - V up to 149 mph - W (consult the tire manufacturer for the specific speed rating) - Z more than 149 mph (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M AND S or M-S (indicating mud and snow traction) imprinted on the side wall. TIRE CHAINS Tire snow chains may be used on certain models. Radial - Ply Tires RADIAL-PLY TIRES Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 2032 Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary. A maximum speed of 80 KPH (50 MPH) is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could also cause inaccurate wheel speed signals when the vehicle is equipped with Anti-Lock Brakes. The use of tires from different manufactures on the same vehicle is NOT recommended. The proper tire pressure should be maintained on all four tires. Tire Pressure for High Speeds TIRE PRESSURE FOR HIGH SPEED Refer to the Vehicles Owners Manual package. Tire Inflation Pressures TIRE INFLATION PRESSURES WARNING: Over or under inflated tires can affect vehicle handling and tread wear. This may cause the tire to fail suddenly, resulting in loss of vehicle control. Under inflation will cause rapid shoulder wear (1), tire flexing, and possible tire failure. Over inflation will cause rapid center wear (1) reduction in the tire's ability to cushion shocks. Improper inflation can cause: - Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 2033 - Vehicle drift For proper tire pressure specification refer to the tire label placard usually located on the drivers door latch pillar. Spare / Temporary Tire SPARE / TEMPORARY TIRE The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 80 KMH (50 MPH). when using the temporary spare tire. Full Size Spare Wheel With Matching Tire FULL SIZE, SPARE WHEEL WITH MATCHING TIRE The spare is a full usage wheel with a matching tire. It can be used within the (posted legal) speed limits or distance limitations as of the rest of the vehicles four tires. Replacement Tires REPLACEMENT TIRES The original equipment tires provide a proper balance of many characteristics such as: - Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. WARNING: Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges Tires: Testing and Inspection Pressure Gauges PRESSURE GAUGES A quality air pressure gauge is recommended to check tire pressure. After checking the air pressure, replace valve cap finger tight. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 2036 Tires: Testing and Inspection Tire Wear Patterns TIRE WEAR PATTERNS Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other. Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 2037 Tires: Testing and Inspection Tire/Vehicle Lead TIRE/VEHICLE LEAD Use the following Vehicle Lead Diagnosis And Correction Chart to diagnose and correct a vehicle lead or drift problem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 2038 Tires: Testing and Inspection Tread Wear Indicators TREAD WEAR INDICATORS Tread wear indicators (3) are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 in.), the tread wear indicators (3) will appear as a 13 mm (1/2 in.) band. Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 2039 Tires: Testing and Inspection Tire Noise Or Vibration TIRE NOISE OR VIBRATION Radial-ply tires are sensitive to force impulses caused by improper mounting, vibration, wheel defects, or possibly tire imbalance. To find out if tires are causing the noise or vibration, drive the vehicle over a smooth road at varying speeds. Note the noise level during acceleration and deceleration. The engine, differential and exhaust noises will change as speed varies, while the tire noise will usually remain constant. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures CLEANING Remove the protective coating on the tires before delivery of a vehicle. This coating may cause deterioration of the tires. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. NOTE: DO NOT use gasoline, mineral oil, oil-based solvent or a wire brush for cleaning. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 2042 Tires: Removal and Replacement TIRE REPAIR AREA For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area (1). The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before removing the tire from the wheel. Use lubrication such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and tighten to proper torque specification. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 2047 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2048 Wheels: Description and Operation DESCRIPTION The rim size is on the vehicle safety certification label located on the drivers door shut face. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges (1) and rim drop well (3) called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2049 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive run out - Dents or cracks - Damaged wheel lug nut holes - Air Leaks from any area or surface of the rim NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. Used wheels are not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: Chrysler LLC does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For Clarification: - Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit. - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Mopar Multi-Purpose Lube NLGI Grade 2 EP, GC-LB Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal Wheel Bearing: Service and Repair Front Hub and Bearing - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 4. Remove the ABS wheel speed sensor if equipped, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor - Removal/Front. 5. Remove the halfshaft nut 4X4 only. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod (2) from the knuckle using puller 8677 (1). 7. Remove the upper ball joint nut and separate the upper ball joint (1) from the knuckle (3) using puller 8677 (2). 8. Pull down on the steering knuckle to separate the half shaft from the hub/bearing. 4X4 only Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 2055 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 2056 Wheel Bearing: Service and Repair Front Hub and Bearing - Installation INSTALLATION 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. 4. Install the ABS wheel speed sensor (4) if equipped See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor - Installation/Front. 5. Install the upper ball joint nut to the steering knuckle and tighten to 75 Nm (55 ft. lbs.). 6. Install the tie rod end nut to the steering knuckle and tighten to 75 Nm (55 ft. lbs.). 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.) 4X4 only. 8. Install the wheel and tire assembly See: Service and Repair/Removal and Replacement. 9. Remove the support and lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications AXLE NUT Half Shaft Nut....................................................................................................................................... ...................................................251 Nm (185 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Lug Nut...................................................................................................................................... ...............................190 ± 13.5 Nm (140 ± 10 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal Wheel Fastener: Service and Repair Wheel Stud - Removal Front FRONT 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 4. Remove the wheel speed sensor from the hub. 5. Press the stud from the hub using remover C-4150A (1). 6. Remove the stud (2) from the hub (1) through the backing plate access hole (3). Rear REAR Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 2066 1. Raise and support the vehicle, See: Vehicle Lifting/Service and Repair. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 4. Using appropriate tools, remove the spring (3) at parking brake adjuster (2). 5. Spread the parking brake shoes (1) apart enough to remove the adjuster (may need to back off adjustment), then remove the adjuster (2). 6. Rotate the axle around until the wheel stud (1) lines up with the opening where the adjuster was removed. 7. Press the stud (1) from the hub using Ball Joint Press C-4150A (3). 8. Remove the stud (1) from the rear of the hub flange. It may be necessary to work the hub flange back and forth to ease stud removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 2067 Wheel Fastener: Service and Repair Wheel Stud - Installation Front FRONT 1. Install the new stud (2) into the hub flange (1). 2. Install three proper sized washers onto the stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten the lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove the lug nut and washers. 5. Install the brake rotor, caliper adapter, and caliper, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. 6. Install the wheel speed sensor. 7. Install the wheel and tire assembly, use new lug nut on the stud or studs that were replaced. 8. Remove the support and lower the vehicle. Rear REAR 1. Install the new stud (4) into the hub flange (2) at the opening where the adjuster was removed. 2. Install three proper sized washers (1) onto the new stud (4), then install a lug nut (3) with the flat side of the nut against the washers. 3. Tighten the lug nut (3) until the stud (4) is pulled into the hub flange (2). Verify that the stud is properly seated into the flange. 4. Remove the lug nut (3) and washers (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 2068 5. Install the parking brake adjuster (2) between the parking brake shoes (1) with the adjuster star wheel near the adjustment window in the brake shield. 6. Using appropriate tools, install the spring (3) at the adjuster (2). 7. Adjust parking brake shoes as necessary, See: Brakes and Traction Control/Parking Brake System/Parking Brake Shoe/Adjustments. 8. Install the brake rotor, caliper adapter and caliper, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. 9. Using a new lug nut on the new stud, install the wheel and tire assembly, See: Service and Repair/Removal and Replacement. 10. Remove the supports and lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service and Repair Jump Starting: Service and Repair JUMP STARTING - HYBRID ELECTRIC VEHICLES (HEV) VEHICLES ONLY WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Review all safety precautions and warnings in the battery system section. See: Starting and Charging/Battery/Service and Repair/Procedures/Battery Charging Do not jump start a frozen battery. - Do not jump start a maintenance-free battery (if equipped) when indicator dot is yellow or a bright color. - Do not jump start a vehicle when the battery fluid is below the top of lead plates. Do not allow jumper cable clamps to touch each other when connected to a booster source. - Do not expose battery to or near open flame. - Remove metallic jewelry worn on hands or wrists to avoid injury by accidental arcing of battery current. - When using a high-output boosting device, do not allow battery voltage to exceed 16 volts. Refer to instructions provided with device being used. Failure to follow these instructions may result in personal injury. CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle. TO JUMP START A DISABLED VEHICLE: This Hybrid vehicle is equipped with both a 12 Volt battery and a high voltage battery. Either battery may become discharged and cause a no crank condition as a result of low voltage. If the 12 Volt battery state of charge is to low and the engine will not crank, the 12 Volt battery light located in the cluster, may illuminate. If this occurs refer to "Jump-Starting - 12 Volt Battery". If the high voltage battery state of charge is too low and the engine will not crank, the navigation radio displays a "Charge Insufficient" message. If this occurs refer to "Jump Assist Procedure High Voltage Battery". Jump Assist Procedure - High Voltage Battery NOTE: When running the Jump Assist mode with the scan tool, ensure the High Voltage Battery contactors are in the close positions. Using the scan tool view the High Voltage Battery contactors status in the BPCM. If the High Voltage Battery contactors are opened, the jump assist will not operate. If this happens, cycle the ignition key from off and on without an attempted crank. The "Jump Assist" procedure allows you to charge the high voltage battery using the 12 Volt battery system. The navigation radio guides you through the "Jump Assist" procedure. This message indicates that the vehicle is in "Jump Assist" mode, and can be charged by following the "Jump Assist" procedure. You have approximately 15 minutes to connect a 12 Volt battery charger and begin charging the system. If you are unable to connect a 12 Volt battery charger within 15 minutes, turn the ignition key to the START position to re-initiate "Jump Assist" mode. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service and Repair > Page 2072 NOTE: - depending on the high voltage battery state of charge, it may take up to 60 minutes for the system to become adequately charged to start the engine. - there are remote battery posts located under the hood that are used to assist in the "Jump Assist" procedure. - a second running vehicle may be used in this "Jump Assist" procedure provided the generator output is a minimum of 125 amps. WARNING: - a battery generates hydrogen gas which is flammable and explosive. Keep flame or spark away from the vent holes. Do Not use a booster battery or any other booster source with a nominal voltage output that exceeds 12 Volts. - battery fluid is a corrosive acid solution; do not allow battery fluid to contact eyes, skin or clothing. If acid splashes in eyes or on skin, flush the contaminated area immediately with large quantities of water. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: - a 12 Volt battery charger with a minimum 30 Amp rating is the only type recommended to use when charging the high voltage battery. - depending on the condition of the second running vehicles alternator and the number of accessories operating on both vehicles, it could take up to 60 minutes to charge the high voltage battery. To minimize the charging time make sure that the minimum amount of accessories are being used. WARNING: Always wear eye protection and remove all metal jewelry such as watch bands or bracelets which might make an unintended electrical contact. Failure to follow these instructions may result in possible serious or fatal injury. 1. Turn off all unnecessary electrical loads such as the heater, radio, lights etc. 2. Set the parking brake, place the transmission in PARK and turn the ignition to the ON/RUN position. 3. Place the battery charger within cable reach of the remote battery posts located under the hood. 4. Connect the positive cable clamp of the 12 Volt battery charger to the remote positive post located near the engine oil dipstick underhood. 5. Connect the negative cable clamp of the 12 Volt battery charger to the remote negative post located near the driver side fender underhood. WARNING: During cold weather when temperatures are below freezing point, electrolyte in a discharged battery may freeze. Do not attempt Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service and Repair > Page 2073 jump-starting because the battery could rupture or explode. The battery temperature must be brought up above freezing point before attempting a jump-start. Failure to follow these instructions may result in possible serious or fatal injury. 6. Place the 12 Volt battery charger to a medium setting and turn ON the battery charger to allow the high voltage battery to charge. CAUTION: Using a setting higher then a medium rate of charge could damage the 12 Volt battery. 7. If the 12 Volt battery charger has been properly connected and the system determines that the conditions are correct for charging, the navigation radio displays a message "CHARGING in Progress". NOTE: To minimize the charging time, it is recommended to leave the key in the OFF position while in the "CHARGING in Progress" mode, however the key may be turned to the ON/RUN position to use an accessory. Allow the system to charge until the navigation radio displays the "Attempt to start vehicle" message. 8. Attempt to start the vehicle, if the vehicle starts, leave it running and turn off the 12 Volt battery charger. 9. Remove the 12 Volt battery charger negative clamp. CAUTION: Be careful of the moving belt and fan blades. 10. Remove the 12 Volt battery charger positive clamp. WARNING: Any procedure other than above could result in: - personal injury caused by electrolyte squirting out the battery vent. - personal injury or property damage due to battery explosion. - damage to charging system or immobilized vehicle. Failure to follow these instructions may result in possible serious or fatal injury. Charging Aborted Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service and Repair > Page 2074 If the "Jump Assist" procedure is interrupted, the navigation radio displays "Charge Aborted". "Jump Assist" can be aborted by the following items: - the key is turned to the START position while the system is being charged. - incorrect installation of the 12 Volt battery charger. - poor cable clamp contact. - the Hybrid Control Module determines conditions are not suitable for charging. If the "Charge Aborted" message is displayed check the battery charger clamps, make sure there is a good connection. Check to see that the 12 Volt battery charger is turned on. Turn off the ignition, wait 10 to 15 seconds and turn the key to the START position. If the "Charge Aborted" message is still active have the vehicle towed to the nearest authorized dealer for service. Jump-Starting - 12 Volt Battery Jumper Cable Clamp Connections WARNING: - battery fluid is a corrosive acid solution; do not allow battery fluid to contact eyes, skin or clothing. Don't lean over battery when attaching clamps or allow the clamps to touch each other. If acid splashes in eyes or on skin, flush the contaminated area immediately with large quantities of water. a battery generates hydrogen gas which is flammable and explosive. Keep flame or spark away from the vent holes. Do not use Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service and Repair > Page 2075 a booster battery or any other booster source with an output that exceeds 12 Volts. Failure to follow these instructions may result in possible serious or fatal injury. Check the Battery Test Indicator (if equipped). If a light or bright colored dot is visible in the indicator (if equipped), Do Not jump-start the battery. If the indicator (if equipped) is dark or shows a green dot, proceed as follows: 1. Wear eye protection and remove all metal jewelry such as watch bands or bracelets which might make an unintended electrical contact. 2. Park the booster vehicle within cable reach but without letting the vehicles touch. Set the parking brake, place the automatic transmission in PARK and turn the ignition off on both vehicles. 3. Turn off heater, radio and all unnecessary electrical loads. 4. Connect one end of a jumper cable (4) to the positive terminal (5) of the booster battery. 5. Connect the other end of the same cable to the remote positive post. WARNING: Do not permit vehicles to touch each other as this could establish a ground connection and personal injury could result. Failure to follow these instructions may result in possible serious or fatal injury. 6. Connect the other cable, first to the negative terminal of the booster battery then to the engine of the vehicle with the discharged battery. Make sure you have a good contact on the engine. WARNING: Do not connect the cable to the negative post of the discharge battery. The resulting electrical spark could cause the battery to explode. During cold weather when temperatures are below freezing point, electrolyte in a discharged battery may freeze. Do not attempt jump-starting because the battery could rupture or explode. The battery temperature must be brought up above freezing point before attempting a jump-start. Failure to follow these instructions may result in possible serious or fatal injury. 7. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery. 8. When removing the jumper cables, reverse the above sequence exactly. Be careful of the moving belts and fan. WARNING: Any procedure other than above could result in: - personal injury caused by electrolyte squirting out the battery vent. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Jump Starting > System Information > Service and Repair > Page 2076 - personal injury or property damage due to battery explosion. - damage to charging system of booster vehicle or of immobilized vehicle. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing Towing Information: Service and Repair Towing SPECIFICATIONS In this article you will find safety tips and information on limits to the type of towing you can reasonably do with the vehicle. Before towing a trailer carefully review this information to tow the load as efficiently and safely as possible. To maintain warranty coverage, follow the requirements and recommendations concerning vehicles used for trailer towing. Common Towing Definitions The following trailer towing related definitions will assist you in understanding the following information: Gross Vehicle Weight Rating (GVWR) The GVWR is the total allowable weight of the vehicle. This includes driver, passengers, cargo and tongue weight. The total load must be limited so that you do not exceed the GVWR. Gross Trailer Weight (GTW) The Gross Trailer Weight (GTW) is the weight of the trailer plus the weight of all cargo, consumables and equipment (permanent or temporary) loaded in or on the trailer in its "loaded and ready for operation" condition. The recommended way to measure GTW is to put the fully loaded trailer on a vehicle scale. The entire weight of the trailer must be supported by the scale. Gross Combination Weight Rating (GCWR) The Gross Combination Weight Rating (GCWR) is the total permissible weight of the vehicle and trailer when weighed in combination. (Note that GCWR ratings include a 150 lbs (68 kg) allowance for the presence of a driver). Gross Axle Weight Rating (GAWR) The GAWR is the maximum capacity of the front and rear axles. Distribute the load over the front and rear axles evenly. Make sure that you do not exceed either front or rear GAWR. WARNING: It is important that you do not exceed the maximum front or rear GAWR. A dangerous driving condition can result if either rating is exceeded. Failure to follow these instructions may result in serious or fatal injury. Tongue Weight (TW) The downward force exerted on the hitch ball by the trailer is the tongue weight. In most cases it should not be less than 10% or more than 15% of the trailer load. You must consider this as part of the load on the vehicle. Frontal Area The maximum height and maximum width of the front of a trailer. TSC (Trailer Sway Control) - If Equipped - Trailer Sway Control - Electronic TSC uses sensors in the vehicle to recognize a swaying trailer and will take the appropriate actions to attempt to stop the sway. The system will reduce engine power and apply individual brakes that will counteract the sway of the trailer. TSC will become active automatically once the swaying trailer is recognized. No driver action is required. TSC cannot stop all trailers from swaying. Always use caution when towing a trailer and follow the tongue weight recommendations. Even if the vehicle is equipped with electronic TSC, mechanical sway control is recommended when appropriate for the size of the trailer. Trailer Sway Control - Mechanical The trailer sway control is a telescoping link that can be installed between the hitch receiver and the trailer tongue that typically provides adjustable friction associated with the telescoping motion to dampen any unwanted trailer swaying motions while traveling. Weight-Carrying Hitch A weight-carrying hitch supports the trailer tongue weight, just as if it were luggage located at a hitch ball or some other connecting point of the vehicle. These kind of hitches are the most popular on the market today and they're commonly used to tow small- and medium-sized trailers. Weight-Distributing Hitch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing > Page 2081 A weight-distributing system works by applying leverage through spring (load) bars. They are typically used for heavier loads, to distribute trailer tongue weight to the tow vehicle's front axle and the trailer axle(s). When used in accordance with the manufacturers' directions, it provides for a more level ride, offering more consistent steering and brake control thereby enhancing towing safety. The addition of a friction/hydraulic sway control also dampens sway caused by traffic and crosswinds and contributes positively to tow vehicle and trailer stability. trailer sway control and a weight distributing (load equalizing) hitch are recommended for heavier tongue weights and may be required depending on vehicle and trailer configuration/loading to comply with Gross Axle Weight Rating (GAWR) requirements. WARNING: An improperly adjusted Weight-Distributing Hitch system may reduce handling, stability, braking performance, and could result in an accident. Weight-Distributing Systems may not be compatible with surge brake couplers. Consult with the hitch and trailer manufacturer or a reputable recreational vehicle dealer for additional information. Failure to follow these instructions may result in serious or fatal injury. Fifth-Wheel Hitch A fifth-wheel hitch is a special high platform with a coupling that mounts over the rear axle of the tow vehicle in the truck bed. Connects a vehicle and fifth-wheel trailer with a coupling king pin. Gooseneck Hitch The gooseneck hitch employs a pivoted coupling arm which attaches to a ball mounted in the bed of a pickup truck. The coupling arm connects to the hitch mounted over the rear axle in the truck bed. Trailer Hitch Classification The rear bumper is intended to tow trailers up to 2,000 lbs (907 kg) without added equipment or alterations to the standard equipment. the vehicle may be factory equipped for safe towing of trailers weighing over 2,000 lbs (907 kg) with the optional Trailer Tow Prep Package. See the authorized dealer for package content. The following chart provides the industry standard for the maximum trailer weight a given trailer hitch class can tow and should be used to assist you in selecting the correct trailer hitch for the intended towing condition. Refer to Trailer Towing Weights (Maximum Trailer Weight Ratings) for the website address that contains the necessary information for the specific drivetrain. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing > Page 2082 All trailer hitches should be professionally installed on the vehicle. Trailer Towing Weights (Maximum Trailer Weight Ratings) Trailer and Tongue Weight Always load a trailer with 60% to 65% of the weight in the front of the trailer. This places 10% to 15% of the Gross Trailer Weight (GTW) on the tow hitch of the vehicle. Loads balanced over the wheels or heavier in the rear can cause the trailer to sway severely side to side which will cause loss of control of vehicle and trailer. Failure to load trailers heavier in front is the cause of many trailer accidents. Never exceed the maximum tongue weight stamped on the bumper or trailer hitch. Consider the following items when computing the weight on the rear axle of the vehicle: - The tongue weight of the trailer. - The weight of any other type of cargo or equipment put in or on the vehicle. - The weight of the driver and all passengers. NOTE: Remember that everything put into or on the trailer adds to the load on the vehicle. Also, additional factory-installed options, or dealer-installed options, must be considered as part of the total load on the vehicle. See: Wheels and Tires/Service and Repair/Procedures Tire and Loading Information placard in the Tire Safety Information section. Towing Requirements To promote proper break-in of the new vehicle drivetrain components the following guidelines are recommended: CAUTION: - Avoid towing a trailer for the first 500 mi (805 km) of vehicle operation. Doing so may damage the vehicle. - During the first 500 mi (805 km) of trailer towing, limit the speed to 50 mph (80 km/h). When towing a trailer, never exceed the GAWR, or GCWR, ratings. WARNING: Improper towing can lead to an injury accident. Follow these guidelines to make the trailer towing as safe as possible: Make certain that the load is secured in the trailer and will not shift during travel. When trailering cargo that is not fully secured, dynamic load shifts can occur that may be difficult for the driver to control. Failure to follow these instructions may result in serious or fatal injury. - When hauling cargo or towing a trailer, do not overload the vehicle or trailer. Overloading can cause a loss of control, poor performance or damage to brakes, axle, engine, transmission, steering, suspension, chassis structure or tires. - Safety chains must always be used between the vehicle and trailer. Always connect the chains to the frame or hook retainers of the vehicle hitch. Cross the chains under the trailer tongue and allow enough slack for turning corners. - Vehicles with trailers should not be parked on a grade. When parking, apply the parking brake on the tow vehicle. Put the tow vehicle automatic transmission in PARK. With a manual transmission, shift the transmission into REVERSE. And with four-wheel drive vehicles, make sure the Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing > Page 2083 transfer case is not in NEUTRAL. Always, block or "chock" the trailer wheels. - GCWR must not be exceeded. - Total weight must be distributed between the tow vehicle and the trailer so that the following four ratings are not exceeded: - GVWR - GTW - GAWR - Tongue weight rating for the trailer hitch utilized (This requirement may limit the ability to always achieve the 10% to 15% range of tongue weight as a percentage of total trailer weight). Towing Requirements - Tires - Do not attempt to tow a trailer while using a compact spare tire. - Proper tire inflation pressures are essential to the safe and satisfactory operation of the vehicle. Refer to the Tires-General Information section on Tire Pressures for proper tire inflation procedures. - Also, check the trailer tires for proper tire inflation pressures before trailer usage. - Check for signs of tire wear or visible tire damage before towing a trailer.See: Wheels and Tires/Tires/Description and Operation section on Tread Wear Indicators for the proper inspection procedure. - When replacing tires See: Wheels and Tires/Tires/Description and Operation section on Replacement Tires for proper tire replacement procedures. Replacing tires with a higher load carrying capacity will not increase the vehicle's GVWR and GAWR limits. Towing Requirements - Trailer Brakes - Do not interconnect the hydraulic brake system or vacuum system of the vehicle with that of the trailer. This could cause inadequate braking and possible personal injury. - An electronically actuated trailer brake controller is required when towing a trailer with electronically actuated brakes. When towing a trailer equipped with a hydraulic surge actuated brake system, an electronic brake controller is not required. - Trailer brakes are recommended for trailers over 1,000 lbs (454 kg) and required for trailers in excess of 2,000 lbs (907 kg). CAUTION: If the trailer weighs more than 454 kg (1,000 lbs) loaded, it should have its own brakes and they should be of adequate capacity. Failure to do this could lead to accelerated brake lining wear, higher brake pedal effort, longer stopping distances and may result in serious or fatal injury. WARNING: Do not connect trailer brakes to the vehicle's hydraulic brake lines. It can overload the brake system and cause it to fail. You might not have brakes when you need them and could have an accident. Towing any trailer will increase the stopping distance. When towing you should allow for additional space between the vehicle and the vehicle in front of you. Failure to follow these instructions may result in serious or fatal injury. Towing Requirements - Trailer Lights AND Wiring Whenever you pull a trailer, regardless of the trailer size, stop lights and turn signals on the trailer are required for motoring safety. The Trailer Tow Package may include a 4- and 7-pin wiring harness. Use a factory approved trailer harness and connector. NOTE: Do not cut or splice wiring into the vehicle's wiring harness. The electrical connections are all complete to the vehicle but you must mate the harness to a trailer connector. Refer to the illustrations and. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing > Page 2084 Towing Tips Before setting out on a trip, practice turning, stopping and backing the trailer in an area away from heavy traffic. If using a manual transmission vehicle for trailer towing, all starts must be in FIRST gear to avoid excessive clutch slippage. Towing Tips - Automatic Transmission The D range can be selected when towing. However, if frequent shifting occurs while in this range, the TOW HAUL feature should be selected. NOTE: Using the TOW HAUL feature while operating the vehicle under heavy operating conditions will improve performance and extend transmission life by reducing excessive shifting and heat build up. This action will also provide better engine braking. The automatic transmission fluid and filter should be changed if you REGULARLY tow a trailer for more than 45 minutes of continuous operation. See: for transmission fluid change intervals. NOTE: Check the automatic transmission fluid level before towing. Towing Tips - Tow/Haul (If Equipped) To reduce potential for automatic transmission overheating, turn the TOW HAUL feature ON when driving in hilly areas or shift the transmission to Drive position 2 on more severe grades. Towing Tips - Electronic Speed Control (If Equipped) - Don't use in hilly terrain or with heavy loads. - When using the speed control, if you experience speed drops greater than 10 mph (16 km/h), disengage until you can resume cruising speed. - Use speed control in flat terrain and with light loads to maximize fuel efficiency. Towing Tips - Cooling System To reduce potential for engine and transmission overheating, take the following actions: - City Driving - When stopped for short periods of time, put transmission in neutral and increase engine idle speed. - Highway Driving - Reduce speed. - Air Conditioning - Turn off temporarily. - Refer to Cooling System Operating information in the Maintenance section for more information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing > Page 2085 Towing Information: Service and Repair Towing Recommendations TOWING RECOMMENDATIONS HEV Vehicles CAUTION: The manufacturer recommends towing with all wheels OFF the ground. Acceptable methods are to tow the vehicle on a flat bed or with one end of the vehicle raised and the opposite end on a towing dolly. A vehicle equipped with SAE- approved wheel lift-type towing equipment can be used to tow all vehicles. When towing a 4WD vehicle using a wheel-lift towing device, use tow dollies under the opposite end of the vehicle. A vehicle with a flat bed device can also be used to transport a disabled vehicle. SAFETY PRECAUTIONS CAUTION: The following safety precautions must be observed when towing a vehicle: - Secure loose and protruding parts. - Always use a safety chain system that is independent of the lifting and towing equipment. - Do not allow towing equipment to contact the disabled vehicle's fuel tank. - Do not allow anyone under the disabled vehicle while it is lifted by the towing device. - Do not allow passengers to ride in a vehicle being towed. - Always observe state and local laws regarding towing regulations. - Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. - Do not attach tow chains, T-hooks, or J-hooks to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. - Do not tow a heavily loaded vehicle. Use a flat bed device to transport a loaded vehicle. GROUND CLEARANCE CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums or rotors. Raise the towed vehicle until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate distance above the ground at the opposite end of the vehicle, especially when towing over rough terrain or steep rises in the road. RAMP ANGLE If towing with flat bed equipment, the approach ramp angle should not exceed 15 degrees. TOWING WHEN KEYS ARE NOT AVAILABLE When the vehicle is locked and keys are not available, tow with flat bed equipment. A wheel-lift device can be used on 4WD vehicles provided all the wheels are lifted off the ground using tow dollies. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing > Page 2086 Towing Information: Service and Repair Recreational Towing (Behind Motorhome, etc.) RECREATIONAL TOWING (BEHIND MOTORHOME, ETC.) OF 4X4 VEHICLES HEV Vehicles CAUTION: Recreational towing of hybrid models is not allowed. Towing the vehicle with the transmission in neutral can cause severe transmission damage. Removal of the driveshaft for towing is not recommended since this allows transmission fluid to leak out. Non-HEV Vehicles WARNING: You or others could be injured if you leave the vehicle unattended with the transfer case in the Neutral (N) position without first fully engaging the parking brake. The transfer case Neutral (N) position disengages both the front and rear driveshafts from the powertrain and will allow the vehicle to move despite the transmission position. The parking brake should always be applied when the driver is not in the vehicle. Failure to follow these instructions may result in possible serious or fatal injury. CAUTION: Internal damage to the transfer case will occur if a front or rear wheel lift is used when recreational towing. NOTE: Because of the design of the transfer cases, only use vehicles equipped with a NV 244 Generation II transfer case should be used for recreational towing. NOTE: The NV 244 Generation II transfer case must be shifted into Neutral (N) for recreational towing. The Neutral (N) selection button is located on the lower left hand corner of the 4WD control switch. Shifts into and out of transfer case Neutral (N) can take place with the selector switch in any mode position. NOTE: If the vehicle is to be towed for multiple days or one day for an eight hour or above duration, disconnect and isolate the battery to prevent discharge due to the illumination of the odometer and PRNDL light. Reset the radio, clock and stations after the negative battery cable is reinstalled. Shifting into Neutral (N) Use the following procedure to prepare your vehicle for recreational towing: CAUTION: It is necessary to follow these steps to be certain that the transfer case is fully in Neutral (N) before recreational towing to prevent damage to internal parts. - Bring vehicle to a complete stop. - Turn the engine OFF. - Place the ignition key in the ON position. - Press the brake pedal. - Shift the automatic transmission to Neutral (N) or press the clutch on manual transmission. - Using the point of a ballpoint pen or similar object, press the recessed transfer case Neutral (N) button for four seconds. - After shift is completed and the Neutral (N) light comes on release Neutral (N) button. - Start the engine. - Shift the automatic transmission into Reverse (R). - Release the brake pedal for five seconds and make sure that there is no vehicle movement. - Repeat steps 9 and 10 with the transmission in Drive (D). - Turn the engine off and place the ignition key to the unlocked OFF position. - Shift the automatic transmission into Park (P). - Attach the vehicle to tow vehicle with a tow bar. NOTE: Items 1 through 5 are requirements that must be met prior to pressing the Neutral (N) selection button, and must continue to be met until the four seconds elapses and the shift has been completed. If any of these requirements (with the exception of 3 - Key on) are not met prior to pressing the Neutral (N) button or are no longer met during the four second timer, then the Neutral (N) indicator light flashes continuously until all requirements are met or until the Neutral (N) button is released. NOTE: The ignition key must be on for a shift to take place and for the position indicator lights to be operable. If the key is not on, the shift will not take place and no position indicator lights will be on or flashing. NOTE: Flashing neutral (N) position indicator light indicates that shift requirements have not been met. CAUTION: Damage to the transmission may occur if the transmission is shifted into Park (P) with the transfer case in Neutral (N) and the engine running. With the transfer case in Neutral (N), make sure the engine is off prior to shifting the transmission into Park (P). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing > Page 2087 Shifting out of Neutral (N) Use the following procedure to prepare your vehicle for normal usage: - Bring the vehicle to a complete stop. - Turn the engine off. - Place the ignition key in the ON position. - Press brake pedal. - Shift the automatic transmission to Neutral (N) or press the clutch on a manual transmission. - Using the point of a ballpoint pen or similar object, press the recessed transfer case Neutral (N) button for one second. - After the Neutral (N) indicator light turns off release the Neutral (N) button. - After the Neutral (N) button has been released the transfer case shifts to the position identified by the selector switch. - Shift the automatic transmission into Drive (D), or release the clutch on a manual transmission. NOTE: Items 1 through 5 are requirements that must be met prior to pressing the Neutral (N) selection button, and must continue to be met until one second elapses and the shift has been completed. If any of these requirements (with the exception of 3 - key on) are not met prior to pressing the Neutral (N) button or are no longer met during the one second time, then all of the mode position indicator lights flashes continuously until all requirements are met or until the Neutral (N) button is released. NOTE: The ignition key must be on for a shift to take place and for the position indicator lights to be operable. If the key is not on, the shift will not take place and no position indicator lights will be on or flashing. NOTE: Flashing neutral (N) position indicator light indicates that shift requirements have not been met. CAUTION: - Do not use a bumper mounted clamp-on tow bar on your vehicle. The bumper face bar will be damaged. - Do not disconnect the rear driveshaft because fluid will leak from the transfer case and damage internal parts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Towing Information > System Information > Service and Repair > Towing > Page 2088 Towing Information: Service and Repair Four Wheel Drive Towing FOUR WHEEL DRIVE TOWING Chrysler Corporation recommends that a vehicle be transported on a flat-bed device. A Wheel-lift device can be used provided all the wheels are lifted off the ground using tow dollies. WARNING: When towing a disabled vehicle and the drive wheels are secured in a wheel lift or tow dollies, ensure the transmission is in the park position. CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended. FOUR WHEEL DRIVE TOWING - REAR END LIFTED WARNING: Ensure vehicle is on a level surface or the wheels are blocked to prevent vehicle from rolling. 1. Attach wheel lift device to front wheels. 2. Place the transmission in neutral. 3. Raise the front of the vehicle off the ground and install tow dollies under front wheels. 4. Attach wheel lift device to rear wheels and raise vehicle to towing position. 5. Attach safety chains to frame rails. Route chains so not to interfere with tail pipe when vehicle is lifted. 6. Turn the ignition switch to the OFF position to unlock the steering wheel. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. 7. Secure steering wheel in straight ahead position with a clamp device designed for towing. 8. Place the transmission in park. FOUR WHEEL DRIVE TOWING - FRONT END LIFTED WARNING: Ensure vehicle is on a level surface or the wheels are blocked to prevent vehicle from rolling. 1. Attach wheel lift device to rear wheels. 2. Place the transmission in neutral. 3. Raise the rear of the vehicle off the ground and install tow dollies under rear wheels. 4. Attach wheel lift device to front wheels and raise vehicle to towing position. 5. Attach the safety chains. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. 6. Turn the ignition switch to the OFF position to unlock the steering wheel. 7. Secure steering wheel in straight ahead position with a clamp device designed for towing. 8. Place the transmission in park. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair HOISTING AND JACKING WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When a chassis or drivetrain component is removed from a vehicle, the center of gravity is altered making some hoisting conditions unstable. Properly support or secure vehicle to hoisting device when these conditions exist. FLOOR JACKING Correct Vehicle Lifting Locations - Typical CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: an axle tube. - aluminum differential. - a body side sill. - a steering linkage component. - a drive shaft. - the engine or transmission oil pan. - the fuel tank. - a front suspension arm. When properly positioned, a floor jack can be used to lift a Durango vehicle. Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. HOISTING A vehicle can be lifted with: - a single-post, frame contact hoist. - a twin-post, chassis hoist. - a ramp-type, drive on hoist. NOTE: When a frame contact type hoist is used, verify that the lifting pads are positioned properly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Diagrams > Multi Displacement System Solenoid CYL 1 (5.7L MDS) (Multi Displacement Solenoid) 2 Way Valve Deactivation Solenoid: Diagrams Multi Displacement System Solenoid CYL 1 (5.7L MDS) (Multi Displacement Solenoid) 2 Way Connector (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY SOLENOID-MULTI DISPLACEMENT SYSTEM CYL 1 (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Diagrams > Multi Displacement System Solenoid CYL 1 (5.7L MDS) (Multi Displacement Solenoid) 2 Way > Page 2099 Valve Deactivation Solenoid: Diagrams Multi Displacement System Solenoid CYL 4 (5.7L MDS) (Multi Displacement Solenoid) 2 Way Connector (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY SOLENOID-MULTI DISPLACEMENT SYSTEM CYL 4 (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Diagrams > Multi Displacement System Solenoid CYL 1 (5.7L MDS) (Multi Displacement Solenoid) 2 Way > Page 2100 Valve Deactivation Solenoid: Diagrams Multi Displacement System Solenoid CYL 6 (5.7L MDS) (Multi Displacement Solenoid) 2 Way Connector (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY SOLENOID-MULTI DISPLACEMENT SYSTEM CYL 6 (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Diagrams > Multi Displacement System Solenoid CYL 1 (5.7L MDS) (Multi Displacement Solenoid) 2 Way > Page 2101 Valve Deactivation Solenoid: Diagrams Multi Displacement System Solenoid CYL 7 (5.7L MDS) (Multi Displacement Solenoid) 2 Way Connector (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY SOLENOID-MULTI DISPLACEMENT SYSTEM CYL 7 (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Description and Operation > MDS System - Description Valve Deactivation Solenoid: Description and Operation MDS System - Description DESCRIPTION The Multiple Displacement System (MDS) provides cylinder deactivation during steady-speed, low-acceleration and shallow grade climbing conditions to increase fuel economy. MDS can provide a 5-20 percent fuel economy benefit when operating in four-cylinder mode, depending on driving habits and vehicle usage. For EPA rating purposes, fuel economy is 8-15 percent higher than if the engine was operating on eight cylinders at all times. MDS is integrated into the basic engine architecture, requiring a minimum of additional parts - four additional solenoids, an oil temperature sensor and a wire harness. Eight unique valve lifters and a modified camshaft are also required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Description and Operation > MDS System - Description > Page 2104 Valve Deactivation Solenoid: Description and Operation MDS System - Operation OPERATION The Multiple Displacement System (MDS) provides cylinder deactivation during steady speed, low acceleration and shallow grade climbing conditions to increase fuel economy. Both four and eight cylinder configurations have even firing intervals provide smooth operation. Two cylinders on each bank are active when the engine is in four-cylinder mode - every other cylinder in the firing order. All of the cylinders that are deactivated have unique hydraulic valve lifters that collapse when deactivated to prevent the valves from opening. Engine oil pressure is used to activate and deactivate the valves. It is delivered through special oil passages drilled into the cylinder block. Solenoid valves control the flow. When activated, pressurized oil pushes a latching pin on each valve lifter, which then becomes a "lost motion" link. Its base follows the camshaft, but its top remains stationary, held in place against the pushrod by light spring pressure but unable to move because of the much higher force of the valve spring. NOTE: It is critical to use the recommended oil viscosity in 5.7L engines that use MDS. Deactivation occurs during the compression stroke of each cylinder, after air and fuel enter the cylinder. Ignition then occurs, but the combustion products remain trapped in the cylinder under high pressure, because the valves no longer open. No air enters or leaves. During subsequent piston strokes, this high-pressure gas is repeatedly compressed and expanded like an air spring, but fuel is not injected. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Description and Operation > MDS System - Description > Page 2105 Valve Deactivation Solenoid: Description and Operation Multiple Displacement Solenoid Description DESCRIPTION The Multi Displacement System selectively deactivates cylinders 1,4,6, and 7, to improve fuel economy. It has two modes of operation: - 8 cylinders for acceleration and heavy loads. - 4 cylinders for cruising and city traffic. The main components of the Multi Displacement System are: - Unique MDS camshaft. - Deactivating roller tappets. - 4 control valves/solenoids. - control valve/solenoid wiring harness. - oil temp sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Description and Operation > MDS System - Description > Page 2106 Valve Deactivation Solenoid: Description and Operation Multiple Displacement Solenoid Operation OPERATION Cylinder Deactivation - Trap an exhaust charge from a normal combustion event - Normal combustion event - Don't open the exhaust valve - Don't open the intake valve - Piston is an air spring - Cylinders deactivated in firing sequence Cylinder Reactivation - Open the exhaust valve - Empty the cylinder - Open the intake valve - Normal combustion event - Cylinders reactivated in firing sequence Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Description and Operation > Page 2107 Valve Deactivation Solenoid: Testing and Inspection MDS SOLENOID The Multi-Displacement System (MDS) has the following detectable issues: - solenoid circuit - fail to deactivate a cylinder(s) - fail to reactivate a cylinder(s) - low oil pressure Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Service and Repair > Multiple Displacement Solenoid - Removal Valve Deactivation Solenoid: Service and Repair Multiple Displacement Solenoid - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Remove the intake manifold See: Intake Manifold/Service and Repair/Removal and Replacement/Intake Manifold - Removal 3. Remove the intake manifold foam insulator pad (1). 4. Remove the electrical connector (1) from the Multi Displacement System (MDS) solenoid(s) (2). 5. Remove the MDS solenoid(s) retaining bolt (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Service and Repair > Multiple Displacement Solenoid - Removal > Page 2110 CAUTION: Do not try to pry the solenoid out. This could lead to breakage and contamination of the lubrication system. 6. While pulling up, rotate the MDS solenoid from side-to-side and remove the MDS solenoid(s) from the cylinder block. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Valve Deactivation Solenoid > Component Information > Service and Repair > Multiple Displacement Solenoid - Removal > Page 2111 Valve Deactivation Solenoid: Service and Repair Multiple Displacement Solenoid - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Verify that the Multi Displacement System (MDS) bores are free of debris before installing the MDS solenoid(s). 2. Install the MDS solenoid(s) (3) making sure the solenoid is completely seated into the cylinder block. 3. Install the MDS solenoid retaining bolt(s) (2) and tighten to 11 Nm (8 ft. lbs.). 4. Connect the MDS electrical connector to the solenoid(s) (3). 5. Install the foam insulator pad (1). 6. Install the intake manifold See: Intake Manifold/Service and Repair/Removal and Replacement/Intake Manifold - Installation 7. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Valve Timing Assembly - Description Variable Valve Timing Actuator: Description and Operation Variable Valve Timing Assembly Description DESCRIPTION The 5.7L Eagle engine is equipped with Variable Cam Timing (VCT). This system advances and/or retards the camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The VCT assembly is sometimes referred to as a camshaft phaser. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. The VCT assembly consists of the camshaft sprocket and a timing phaser. The VCT phaser assembly bolts to the camshaft and is serviced as an assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Valve Timing Assembly - Description > Page 2116 Variable Valve Timing Actuator: Description and Operation Variable Valve Timing Assembly Operation OPERATION The Variable Cam Timing (VCT) assembly is actuated with engine oil pressure. The oil flow to the VCT assemblies are controlled by an Oil Control Valve (OCV). The OCV consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VCT assemblies. The VCT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VCT assembly rotates the rotor with respect to the stator, thus rotating the exhaust camshaft with respect to the timing chain and intake camshaft. An infinitely variable cam timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Service and Repair > Variable Valve Timing Assembly - Removal Variable Valve Timing Actuator: Service and Repair Variable Valve Timing Assembly - Removal REMOVAL CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. 1. Remove the timing chain and sprockets See: Timing Components/Timing Chain/Service and Repair/Timing Chain & Sprockets - Removal 2. Remove the camshaft phaser bolt (1). 3. Remove camshaft phaser (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Actuator > Component Information > Service and Repair > Variable Valve Timing Assembly - Removal > Page 2119 Variable Valve Timing Actuator: Service and Repair Variable Valve Timing Assembly - Installation INSTALLATION 1. Align the slot (2) in the phaser (1) with the dowel on the camshaft. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. 2. Position the phaser (2) in place and install phaser retaining bolt (1) and tighten to 122 Nm (90 ft. lbs.). 3. Install the timing chain and sprockets See: Timing Components/Timing Chain/Service and Repair/Timing Chain & Sprockets - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Diagrams Variable Valve Timing Solenoid: Diagrams Connector (5.7L) - 2 WAY SOLENOID-VARIABLE CAMSHAFT TIMING (5.7L) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation > Oil Intake Control Valve - Operation Variable Valve Timing Solenoid: Description and Operation Oil Intake Control Valve - Operation OPERATION The Variable Valve Timing (VVT) assembly is actuated with engine oil pressure. The oil flow to the VVT assemblies are controlled by an Oil Control Valve (OCV). The OCV consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VVT assemblies. The VVT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VVT assembly rotates the rotor with respect to the stator, thus rotating the exhaust camshaft with respect to the timing chain and intake camshaft. An infinitely variable valve timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Description and Operation > Oil Intake Control Valve - Operation > Page 2125 Variable Valve Timing Solenoid: Description and Operation Oil Intake Control Valve - Description DESCRIPTION The 5.7L engine is equipped with Variable Valve Timing (VVT). This system uses an oil control valve to direct oil pressure into the camshaft phaser assembly. The camshaft phaser assembly advances and/or retards camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The oil control valve is located under the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Oil Intake Control Valve - Installation Variable Valve Timing Solenoid: Service and Repair Oil Intake Control Valve - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Install the oil control valve (OCV) (1). 2. Securely tighten the OCV fastener. 3. Connect the OCV electrical connector (2). 4. Install the intake manifold See: Intake Manifold/Service and Repair/Removal and Replacement/Intake Manifold - Installation 5. Connect the 12 volt battery system ground isolation connector (1) located next to the electric vacuum pump (2). 6. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Oil Intake Control Valve - Installation > Page 2128 Variable Valve Timing Solenoid: Service and Repair Oil Intake Control Valve - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the fuel system pressure release procedure See: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Disconnect the 12 volt battery system ground isolation connector (1) located next to the electric vacuum pump (2). 3. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 4. Remove the intake manifold See: Intake Manifold/Service and Repair/Removal and Replacement/Intake Manifold - Removal 5. Disconnect the oil control valve (OCV) electrical connector (2). 6. Remove the OCV fastener (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve Timing Solenoid > Component Information > Service and Repair > Oil Intake Control Valve - Installation > Page 2129 NOTE: To remove the oil control valve, the engine must be at room temperature. 7. Rotate the OCV to break the seal and pull the OCV out of the cylinder block. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications PRESSURE/VARIATION Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2133 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE LEAKAGE NOTE: The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. NOTE: Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs and record the cylinder number of each spark plug for future reference. 3. Inspect the spark plug electrodes for abnormal firing indicators such as fouled, hot, oily, etc. 4. Disable the fuel system See: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair and perform the fuel system pressure release procedure. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 7. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 8. If one or more cylinders have abnormally low compression pressures, repeat the compression test. NOTE: If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. 9. If one or more cylinders continue to have abnormally low compression pressures, perform the cylinder combustion pressure leakage test See: Testing and Inspection/Component Tests and General Diagnostics/Cylinder Combustion Pressure Leakage Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications CAMSHAFT GEAR/SPROCKET Camshaft Sprocket Bolt........................................................................................................................ .....................................................122 Nm (90 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures Camshaft: Procedures INSPECTION The cam bearings are not serviceable. Do not attempt to replace cam bearings for any reason. If the cam bearings are damaged, the cylinder block must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2142 Camshaft: Removal and Replacement Camshaft - Removal CAMSHAFT WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the fuel system pressure release procedure See: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 3. Disconnect the 12 volt battery system ground isolation connector (1) and remove the connector from the electric vacuum pump bracket (2). 4. Disconnect the high voltage inter lock (HVIL) electrical connector (1). 5. Remove the clean air tube retaining bolt (3). 6. Remove the clean air tube (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2143 7. Remove the center air cleaner trim cover (2) with a small screwdriver (1). 8. Disconnect the intake air temperature (IAT) sensor electrical connector (1). 9. Disconnect the brake booster hose and positive crankcase ventilation (PCV) hose. 10. Remove the center air cleaner retaining bolt (2). 11. Slightly raise the front of the air cleaner housing (3) up off the throttle body. 12. Slide the air cleaner housing forward to remove the rear air cleaner housing pegs (2) from the grommets (1) on the rear of the intake manifold. 13. Remove the air cleaner housing from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2144 14. Remove the water pump drive belt (1) See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal WARNING: Do not remove the radiator pressure cap, cylinder block drain plugs or loosen the radiator draincock with the system hot and under pressure. Serious burns from coolant can occur. 15. Loosen the radiator petcock. 16. Remove the cylinder block drain plugs (1) and completely drain the cooling system. 17. Remove the radiator See: Cooling System/Radiator/Service and Repair/Removal and Replacement/Engine Cooling Radiator - Removal 18. Remove the left and right cylinder heads See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head Removal 19. Remove the oil pan See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Removal 20. Remove the timing case cover See: Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Removal Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2145 NOTE: Identify the lifter(s) to make sure they are installed in their original location(s). 21. Remove the tappets (2) and retainer (1) assembly. 22. Remove the oil pick-up tube fasteners (2). 23. Remove the oil pick-up tube (1). 24. Remove the oil pump retaining bolts (2) and remove the oil pump (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2146 25. Remove the timing chain (5) See: Timing Components/Timing Chain/Service and Repair/Timing Chain & Sprockets - Removal 26. Remove the camshaft thrust plate (1). NOTE: Slowly rotate the camshaft while pulling the camshaft out. 27. Install a long bolt (2) into the front of the camshaft (1) to aid in the removal of the camshaft. Remove the camshaft, being careful not to damage the cam bearings with the cam lobes. Camshaft - Installation CAMSHAFT Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2147 WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Lubricate the camshaft lobes and camshaft bearing journals and insert the camshaft. 2. Using the sequence shown, position the camshaft thrust plate and install the retaining bolts and tighten to 28 Nm (21 ft. lbs.). 3. Install the timing chain (5), crankshaft sprocket (3) and camshaft phaser (1) and tighten the camshaft phaser bolt to 122 Nm (90 ft. lbs.).See: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2148 Timing Components/Timing Chain/Service and Repair/Timing Chain & Sprockets - Installation 4. Measure the camshaft end play, if not within limits install a new thrust plate See: Specifications/Engine Specifications 5. Align the oil pump drive with the crankshaft and install the oil pump See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement 6. Install a new O-ring on the oil pick up tube (1) and lubricate the O-ring with clean engine oil. 7. Install the oil pick up tube (1) and tighten the bolts (2) to 28 Nm (21 ft. lbs.). 8. Install the oil pan See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Installation CAUTION: 5.7L engines equipped with the Multi-Displacement System (MDS) uses both standard roller tappets and deactivating roller tappets. The deactivating roller tappets must be used in cylinders 1,4,6,7. The deactivating tappets can be identified by the two holes in the side of the tappet body, for the latching pins. CAUTION: When replacing the camshaft, all of the lifters must be replace or severe engine damage may occur. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2149 NOTE: If the tappets are to be reused, they must be installed in the same position from which they were removed. NOTE: The lifters are serviced in sets of four with the retainer. 9. Install the MDS rear lifter assemblies (2) and tighten retaining bolt to 12 Nm (9 ft. lbs.). 10. Install the MDS front lifter assemblies (2) and tighten retaining bolt to 12 Nm (9 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2150 11. Install both left and right cylinder heads (4) See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head Installation. 12. Install the pushrods. 13. Install the rocker arms See: Rocker Arm Assembly/Service and Repair/Valve Rocker Arm - Installation 14. Install the timing case cover See: Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2151 15. Using the sequence shown, install the cylinder head covers and tighten the bolts to 8 Nm (71 lbs. in.). 16. Install the intake manifold See: Intake Manifold/Service and Repair/Removal and Replacement/Intake Manifold - Installation 17. Install the water pump drive belt (1) See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation 18. Install the radiator See: Cooling System/Radiator/Service and Repair/Removal and Replacement/Engine Cooling Radiator - Installation 19. Connect the 12 volt battery system ground isolation connector (1) and attach the connector to the electric vacuum pump bracket (2). 20. Connect the electric vacuum pump electrical connector (4). 21. Connect the vacuum hose (3) to the vacuum pump (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2152 22. Verify the throttle body seal is properly aligned at the bottom of the air cleaner housing. 23. Slide the rear air cleaner pegs (2) into the grommets (1) on the rear of the intake manifold and lower the front of the air cleaner housing onto the throttle body. NOTE: Verify the air cleaner is installed properly in the rear grommets by reaching around the left rear corner of the air cleaner and feeling for the pegs protruding through the rubber grommets. If the plastic pegs cannot be felt, the air cleaner will need to be reinstalled. 24. Install the air cleaner housing center retaining bolt (2) and tighten to 7 Nm (62 in. lbs.) 25. Install the center air cleaner trim cover. 26. Connect the intake air temperature (IAT) sensor electrical connector (1). 27. Install the clean air tube (2). 28. Install the clean air tube fastener (3) and tighten to 7 Nm (62 in. lbs.). 29. Connect the high voltage inter lock (HVIL) electrical connector. 30. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 31. Fill the engine with coolant See: Cooling System/Service and Repair 32. Fill the engine with oil See: Engine Lubrication/Engine Oil/Service and Repair 33. Start the engine and check for leaks. Camshaft Core Hole Plug - Removal CAMSHAFT CORE HOLE PLUG WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the fuel system pressure release procedure See: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Service and Repair > Procedures > Page 2153 2. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 3. Remove the engine from the vehicle See: Service and Repair/Removal and Replacement/Engine - Removal CAUTION: Do not damage the rear surface of the camshaft or the core plug sealing surface, when removing the core plug. 4. Using a suitable sharp punch, punch a small hole in the camshaft core hole plug (1). 5. Insert a short sheet metal screw into the small hole in the camshaft core hole plug. 6. Using a suitable slide hammer puller, remove the rear camshaft core hole plug. Camshaft Core Hole Plug - Installation CAMSHAFT CORE HOLE PLUG 1. Clean the core hole in the cylinder block. NOTE: Do not apply adhesive to the new camshaft core hole plug. A new plug has adhesive pre-applied. 2. Install a new camshaft core hole plug (1) located at the rear of cylinder block, using a suitable flat faced tool. The plug must be fully seated on the cylinder block shoulder. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Description and Operation > Hydraulic Lifters - Description Lifter / Lash Adjuster: Description and Operation Hydraulic Lifters - Description DESCRIPTION The Multiple Displacement System (MDS) provides cylinder deactivation during steady speed, low acceleration and shallow grade climbing conditions to increase fuel economy. The MDS can provide a 5 to 20 percent fuel economy benefit when operating in four-cylinder mode. Depending on driving habits and vehicle usage. Fuel economy is 8 to 15 percent higher than if the engine was operating on eight-cylinders at all times. MDS is integrated into the basic engine architecture, requiring a minimum of additional parts - four additional solenoids, an oil temperature sensor, a wire harness, eight unique valve lifters (1), and a modified camshaft. The MDS lifter (1) can be identified by the disconnecting pin (3) on the side of the lifter. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Description and Operation > Hydraulic Lifters - Description > Page 2158 Lifter / Lash Adjuster: Description and Operation Hydraulic Lifters - Operation OPERATION The Multiple Displacement System (MDS) provides cylinder deactivation during steady speed, low acceleration and shallow grade climbing conditions to increase fuel economy. Both four and eight cylinder configurations have even firing intervals provide smooth operation. Two cylinders on each bank are active when the engine is in four-cylinder mode - every other cylinder in the firing order. All of the cylinders that are deactivated have unique hydraulic valve lifters that collapse when deactivated to prevent the valves from opening. Engine oil pressure is used to activate and deactivate the valves. It is delivered through special oil passages drilled into the cylinder block. Solenoid valves control the flow. When activated, pressurized oil pushes a latching pin on each valve lifter, which then becomes a "lost motion" link. Its base follows the camshaft, but its top remains stationary, held in place against the pushrod by light spring pressure but unable to move because of the much higher force of the valve spring. NOTE: It is critical to use the recommended oil viscosity in 5.7L engines that use MDS. Deactivation occurs during the compression stroke of each cylinder, after air and fuel enter the cylinder. Ignition then occurs, but the combustion products remain trapped in the cylinder under high pressure, because the valves no longer open. No air enters or leaves. During subsequent piston strokes, this high-pressure gas is repeatedly compressed and expanded like an air spring, but fuel is not injected. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Description and Operation > Page 2159 Lifter / Lash Adjuster: Testing and Inspection HYDRAULIC TAPPETS Check the oil pressure before disassembling any part of the engine to correct tappet noise. If vehicle has no oil pressure gauge, install a reliable gauge at the pressure sending-unit. The pressure should be between 207-552 kPa (30-80 psi) at 3,000 RPM. Check the oil level after the engine reaches normal operating temperature. Allow five minutes for the oil level to stabilize before checking the oil level. The oil level in the pan should never be above the FULL mark or below the ADD OIL mark on the dipstick. Either of these two conditions could be responsible for noisy tappets. OIL LEVEL HIGH If the oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil. With the engine running, this condition could create foam in the oil pan. Foam in the oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow the valves to seat noisily. LOW Low oil level may allow the oil pump to take in air. When air is fed to the tappets, they lose length, which allows valves to seat noisily. Any leaks on the intake side of the oil pump through which air can be drawn creates the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than one tappet will be noisy. When the oil level and leaks have been corrected, operate the engine at fast idle. Run the engine for a sufficient amount of time to allow all of the air inside the tappets to be bleed out. TAPPET NOISE DIAGNOSIS 1. To determine the source of tappet noise, crank the engine over with the cylinder head covers removed. 2. Feel each valve spring or rocker arm to detect the noisy tappet. The noisy tappet will cause the affected spring and/or rocker arm to vibrate or feel rough in operation. NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm pushrod sockets and pushrod ends for wear. 3. Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by excessive leak-down around the unit plunger, or by the plunger partially sticking in the tappet body cylinder. The tappet should be replaced. A heavy click is caused by a tappet check valve not seating, or by foreign particles wedged between the plunger and the tappet body. This will cause the plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, tappet assembly should be removed for inspection and cleaning. 4. The valve train generates a noise very much like a light tappet noise during normal operation. Care must be taken to ensure that tappets are making the noise. If more than one tappet seems to be noisy, it's probably not the tappets. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Hydraulic Lifters - Removal Lifter / Lash Adjuster: Service and Repair Hydraulic Lifters - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the 12 volt battery system ground isolation connector (1). 3. Remove the cylinder head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal 4. Remove the tappet guide holder retaining bolt (1) from the tappet guide holder assembly (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Hydraulic Lifters - Removal > Page 2162 CAUTION: The tappets and guide holder assembly must be installed as an assembly and in their original locations or engine damage could result. CAUTION: If the tappets and guide holder assembly are to be reused, identify tappets to ensure installation in their original location. 5. Remove the tappet guide holder (1) and tappets (2) as an assembly. 6. Check the camshaft lobes for abnormal wear. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Hydraulic Lifters - Removal > Page 2163 Lifter / Lash Adjuster: Service and Repair Hydraulic Lifters - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions The Multiple Displacement System (MDS) provides cylinder deactivation during steady speed, low acceleration and shallow grade climbing conditions to increase fuel economy. CAUTION: Engines equipped with MDS use both standard roller tappets (2) and deactivating roller tappets (1). The deactivating roller tappets must be used in cylinders 1,4,6,7. The deactivating tappets can be identified by the two holes in the side of the tappet body (3), for the latching pins. CAUTION: The tappets and guide holder assembly must be installed as an assembly and in their original locations or engine damage could result. 1. Lubricate the tappet guide holder (1) and tappets (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Hydraulic Lifters - Removal > Page 2164 CAUTION: If the tappets and guide holder assembly are to be reused, they must me installed in their original location. 2. Install the tappet guide holder (2) and tappets. 3. Tighten the tappet retainer bolt (1) to 12 Nm (106 in. lbs.). 4. Install the cylinder head See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Installation 5. Install the air cleaner assembly See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body Installation 6. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up CAUTION: To prevent damage to valve assemblies, do not run the engine above fast idle until all hydraulic tappets have filled with oil and have become quiet. 7. Start the engine and check for leaks. 8. Road test the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Valve Rocker Arm - Removal Rocker Arm Assembly: Service and Repair Valve Rocker Arm - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Remove the ignition coils (1) See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil - Removal 3. Remove the cylinder head cover See: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Valve Rocker Arm - Removal > Page 2169 4. Install the pushrod retainer (1) 9070. 5. Using the sequence shown, remove the rocker shafts assembly retaining bolts. CAUTION: The rocker shaft assemblies are not interchangeable between the intake and the exhaust, failure to install them in the correct location could result in engine damage. The intake rocker arms (1) are marked with the letter "I" (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Valve Rocker Arm - Removal > Page 2170 CAUTION: Do not remove the retainers (1) from the rocker shaft (3). 6. Remove the rocker shaft assembly (3). Note the rocker shaft location during removal. CAUTION: The longer pushrods are for the exhaust side and the shorter pushrods are for the intake side. 7. Remove the pushrods. Note the pushrod location during removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Valve Rocker Arm - Removal > Page 2171 Rocker Arm Assembly: Service and Repair Valve Rocker Arm - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions CAUTION: The longer pushrods are for the exhaust side and the shorter pushrods are for the intake side. 1. Install the pushrods in the same order as removed. 2. Install the pushrod retainer (1) 9070. CAUTION: Make sure that the retainers (1) and the rocker arms (2) are not overlapped when tightening bolts or engine damage could result. CAUTION: Due to the changes in the pushrod clearance holes in the Eagle 5.7L cylinder heads, close attention must be given when installing the pushrod(s) into the tappet(s). Once the pushrod(s) have been installed, use a suitable light to look down through the pushrod hole(s). This will allow you to verify the pushrod(s) are centered properly in the tappet(s) and avoid engine damage. Recheck after the rocker shaft assembly has been installed and tightened to specification. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Valve Rocker Arm - Removal > Page 2172 CAUTION: The rocker shaft assemblies are not interchangeable between the intake and the exhaust, failure to install them in the correct location could result in engine damage. The intake rocker arms (1) are marked with the letter "I" (2). 3. Install the rocker shaft assemblies in the same order as removed. 4. Using the sequence shown, tighten the rocker shaft bolts to 22 Nm (16 ft. lbs.). CAUTION: Do Not rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about five minutes). 5. Remove the pushrod retainer (1) 9070. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Valve Rocker Arm - Removal > Page 2173 6. Install the cylinder head cover See: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Installation 7. Install the ignition coils (1) See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil - Removal 8. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 9. Start the engine and inspect for leaks. 10. Road test the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Valve Timing Assembly - Description Variable Valve Timing Actuator: Description and Operation Variable Valve Timing Assembly Description DESCRIPTION The 5.7L Eagle engine is equipped with Variable Cam Timing (VCT). This system advances and/or retards the camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The VCT assembly is sometimes referred to as a camshaft phaser. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. The VCT assembly consists of the camshaft sprocket and a timing phaser. The VCT phaser assembly bolts to the camshaft and is serviced as an assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Valve Timing Assembly - Description > Page 2178 Variable Valve Timing Actuator: Description and Operation Variable Valve Timing Assembly Operation OPERATION The Variable Cam Timing (VCT) assembly is actuated with engine oil pressure. The oil flow to the VCT assemblies are controlled by an Oil Control Valve (OCV). The OCV consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VCT assemblies. The VCT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VCT assembly rotates the rotor with respect to the stator, thus rotating the exhaust camshaft with respect to the timing chain and intake camshaft. An infinitely variable cam timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Service and Repair > Variable Valve Timing Assembly - Removal Variable Valve Timing Actuator: Service and Repair Variable Valve Timing Assembly - Removal REMOVAL CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. 1. Remove the timing chain and sprockets See: Timing Components/Timing Chain/Service and Repair/Timing Chain & Sprockets - Removal 2. Remove the camshaft phaser bolt (1). 3. Remove camshaft phaser (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve Timing Actuator > Component Information > Service and Repair > Variable Valve Timing Assembly - Removal > Page 2181 Variable Valve Timing Actuator: Service and Repair Variable Valve Timing Assembly - Installation INSTALLATION 1. Align the slot (2) in the phaser (1) with the dowel on the camshaft. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. 2. Position the phaser (2) in place and install phaser retaining bolt (1) and tighten to 122 Nm (90 ft. lbs.). 3. Install the timing chain and sprockets See: Timing Components/Timing Chain/Service and Repair/Timing Chain & Sprockets - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications CONNECTING RODS Journal Diameter ................................................................................................................................. ................................. 53.992 - 54.008 mm (2.126 in.) Bearing Clearance........................................... ............................................................................................................0.020 - 0.060 mm (0.0007 0.0023 in.) Bearing Bore Out of Round (MAX)..................................................................................... .................................................................0.005 mm (0.0002 in.) Taper (MAX) ................................... .................................................................................................................................................. 0.003 mm (0.0001 in.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications CONNECTING RODS Side Clearance..................................................................................................................................... ............................0.10 - 0.35 mm ( 0.003 - 0.0137 in.) Connecting Rod Journal Diameter..........................................................................................................................64.988 65.012 mm (2.5585 - 2.5595 in.) ROD BEARING CAP Connecting Rod Cap Bolts................................................................................................................... ..................................21 Nm (15 ft. lbs.) plus 90° turn Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2189 Connecting Rod: Description and Operation DESCRIPTION CAUTION: Do not use a metal stamp to mark connecting rods as damage may result, instead use ink or a scratch awl. The pistons are made of a high strength aluminum alloy. Piston skirts are coated with a solid lubricant (Molykote(R)) to reduce friction and provide scuff resistance. The piston top ring groove and land is anodized. The connecting rods are made of forged powdered metal, with a fractured cap design. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures Connecting Rod: Procedures Piston and Connecting Rod - Cleaning CLEANING CAUTION: Do not use a wire wheel or other abrasive cleaning devise to clean the pistons or connecting rods. The pistons have a moly coating, this coating must not be damaged. 1. Using a suitable cleaning solvent, clean the pistons in warm water and towel dry. 2. Use a wood or plastic scraper to clean the ring land grooves. CAUTION: Do not remove the piston pin from the piston and connecting rod assembly. Piston and Connecting Rod - Inspection INSPECTION Check the connecting rod journal for excessive wear, taper and scoring.See: . Check the connecting rod for signs of twist or bending. Check the piston for taper and elliptical shape before it is fitted into the cylinder bore. See: . Check the piston for scoring or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration. Piston Fitting PISTON FITTING 1. To correctly select the proper size piston, a cylinder bore gauge (2), capable of reading in 0.003 mm (0.0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer. 2. Measure the inside diameter of the cylinder bore at a point 38.0 mm (1.5 inches) below top of bore (4). Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A (1) and then take an additional bore reading 90 degrees to that at point B (1). 3. The coated pistons will be serviced with the piston pin and connecting rod pre-assembled. The piston-rod assembly is specific for the left cylinder bank (odd numbered) and the right cylinder bank (even numbered) and must not be interchanged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 2192 4. Measure the piston diameter with a micrometer at points (1,2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 2193 Connecting Rod: Removal and Replacement Piston and Connecting Rod - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Using the sequence shown, remove the oil pan bolts and remove the oil pan and gasket/windage tray See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Removal 3. Remove the cylinder heads See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal 4. If necessary, remove the ridge from the top of the cylinder bores with a reliable ridge reamer before removing the pistons from the cylinder block. Be sure to keep the tops of the pistons covered during this operation. NOTE: When removing the piston and connecting rod assemblies from the engine, rotate the crankshaft until each connecting rod is centered in the cylinder bore. CAUTION: Do not use a number stamp or a punch to mark the connecting rods or caps, as damage to the connecting rods could occur. NOTE: The connecting rods and bearing caps are not interchangeable and should be marked before removal to make sure they are installed in their original locations. 5. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 2194 CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur. 6. Remove the connecting rod cap and install the connecting rod guides 8507 (1) into the connecting rod being removed. Remove the piston from the cylinder bore. Repeat this procedure for each piston being removed. 7. Immediately after rod removal, install the bearing cap on the connecting rod to prevent damage to the fractured cap and rod surfaces. 8. Remove the piston rings from the piston(s). Piston and Connecting Rod - Installation INSTALLATION NOTE: Before reinstalling used rings or installing new rings, the ring clearances must be checked. 1. Check piston ring clearance See: Piston Ring/Service and Repair NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs. 2. Install the piston rings onto the pistons See: Piston Ring/Service and Repair 3. Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten the piston ring compressor. Make sure the piston ring position does not change during this procedure. 4. Position the bearing (1) onto the connecting rod. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 2195 5. Install special tool 8507 connecting rod guides (1) onto the connecting rod bolt threads. 6. Lubricate the bearing surface with clean engine oil. 7. The pistons are marked by an arrow on the top of the piston indicating installation position. This mark must be pointing toward the front of the engine on both cylinder banks. 8. Wipe the cylinder bore clean and lubricate with clean engine oil. 9. Rotate the crankshaft until the connecting rod journal is centered with the cylinder bore. Insert the piston and rod assembly into the cylinder bore and carefully position the connecting rod guides over the crankshaft journal. 10. Tap the piston down into the cylinder bore using a hammer handle while guiding the connecting rod into position on the rod journal. CAUTION: The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Service and Repair > Procedures > Page 2196 11. Wipe the connecting rod cap (1) clean and lubricate with clean engine oil and install the bearing (3). 12. Remove special tool 8507 connecting rod guides. NOTE: The connecting rods and bearing caps are not interchangeable, line up the previously marked bearing caps and connecting rods to ensure assembly to their original location. 13. Lubricate the bearing surfaces with clean engine oil and position the rod cap in place. 14. Lubricate the new rod bolts with clean engine oil. 15. Install the new and lubricated rod bolts and tighten to 21 Nm (15 ft. lbs.) plus a 90° turn. 16. Install the cylinder head(s) See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Installation 17. Install the timing chain cover See: Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Installation 18. Install the cylinder head covers See: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Installation 19. Install the intake manifold See: Intake Manifold/Service and Repair/Removal and Replacement/Intake Manifold - Installation 20. Install the new oil pan gasket/windage tray and oil pan See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Installation 21. Fill the engine with oil See: Engine Lubrication/Engine Oil/Service and Repair Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications MAIN BEARING Main Bearing Journal Diameter..............................................................................................................................64.988 65.012 mm (2.5585 - 2.5595 in.) Bearing Clearance........................................................................... ..............................................................................0.023 - 0.051 mm (0.0009 - 0.002 in.) Out of Round (MAX)........................................................................................................................................ ....................................0.005 mm (0.0002 in.) Taper (MAX)................................................................. .......................................................................................................................0.003 mm (0.0001 in.) MAIN BEARING SELECTION CHART MAIN BEARING CAP Tighten main bearing cap bolts to.........................................................................................................................13 Nm ( 10 ft. lbs.) in the sequence shown. Tighten main bearing cap bolts to.........................................................................................................................27 Nm ( 20 ft. lbs.) in the sequence shown. Rotate main cap bolts an additional 90° in the sequence shown. Tighten cross bolt to 28 Nm ( 21 ft. lbs.). Repeat cross bolt tightening procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Crankshaft Main Bearing Fitting Crankshaft Main Bearing: Service and Repair Crankshaft Main Bearing Fitting CRANKSHAFT MAIN BEARING - FITTING MAIN BEARING JOURNAL DIAMETER (CRANKSHAFT REMOVED) With the crankshaft removed from the cylinder block. Clean the oil off the main bearing journal. Determine the maximum diameter of the journal with a micrometer. Measure at two locations 90° apart at each end of the journal. The maximum allowable taper is 0.008mm (0.0004 inch.) and maximum out of round is 0.005mm (0.0002 inch). Compare the measured diameter with the journal diameter specification (Main Bearing Fitting Chart). Select the inserts required to obtain the specified bearing-to-journal clearance. CRANKSHAFT MAIN BEARING SELECTION The main bearings are "select fit" to achieve proper oil clearances. For main bearing selection, the crankshaft counterweight has grade identification marks stamped into it. These marks are read from left to right.The left letter (1) refers to the number one main journal and the right letter (2) refers to the number 5 journal. NOTE: Service main bearings are coded. These codes identify what size or grade of the bearing. MAIN BEARING SELECTION CHART - 5.7L Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Service and Repair > Crankshaft Main Bearing Fitting > Page 2202 Crankshaft Main Bearing: Service and Repair Crankshaft Main Bearing Inspection INSPECTION Wipe the inserts clean and inspect for abnormal wear patterns and for metal or other foreign material imbedded in the lining. Normal main bearing insert wear patterns are illustrated. NOTE: If any crankshaft journals are scored, the crankshaft must be repaired or replaced. Inspect the back of the inserts for fractures, scrapings or irregular wear patterns. Inspect the upper insert locking tabs for damage. Replace all damaged or worn bearing inserts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Crankshaft Rear Oil Seal Retainer - Removal Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Retainer - Removal REMOVAL NOTE: The crankshaft rear oil seal is integral to the crankshaft rear oil seal retainer and must be replaced as an assembly. NOTE: The crankshaft rear oil seal retainer can not be reused after removal. NOTE: This procedure can be performed in vehicle. 1. Disconnect the negative battery cable. 2. Remove the transmission. 3. Remove the flexplate See: Transmission and Drivetrain/Flex Plate/Service and Repair/Flexplate - Removal 4. Remove the oil pan See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Removal 5. Using the sequence shown, remove the rear oil seal retainer mounting bolts. 6. Carefully remove the retainer from the engine block. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Crankshaft Rear Oil Seal Retainer - Removal > Page 2207 Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal Retainer - Installation INSTALLATION NOTE: The crankshaft rear oil seal is integral to the crankshaft rear oil seal retainer and must be replaced as an assembly. NOTE: The crankshaft rear oil seal retainer can not be reused after removal. 1. Thoroughly clean all gasket residue from the engine block. 2. Position the gasket onto the new crankshaft rear oil seal retainer. 3. Position the crankshaft rear oil seal retainer onto the engine block. 4. Using the sequence shown, install the crankshaft rear oil seal retainer mounting bolts and tighten to 15 Nm (11 ft. lbs.). 5. Install the oil pan See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Installation 6. Install the flexplate See: Transmission and Drivetrain/Flex Plate/Service and Repair/Flexplate - Installation 7. Install the transmission. 8. Fill the engine with oil. 9. Start the engine and check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications CRANKSHAFT Bearing Clearance................................................................................................................................ .......................0.020 - 0.060 mm (0.0007 - 0.0023 in.) Out of Round (MAX)....................................... .....................................................................................................................................0.005 mm (0.0002 in.) Taper (MAX)...................................................................................................................... ..................................................................0.003 mm (0.0001 in.) Main Bearing Journal Diameter..............................................................................................................................64.988 65.012 mm (2.5585 - 2.5595 in.) Bearing Clearance........................................................................... ..............................................................................0.023 - 0.051 mm (0.0009 - 0.002 in.) Out of Round (MAX)........................................................................................................................................ ....................................0.005 mm (0.0002 in.) Taper (MAX)................................................................. .......................................................................................................................0.003 mm (0.0001 in.) End Play............................................................................................................................................... ...........................0.052 - 0.282 mm (0.002 - 0.011 in.) End Play (MAX).............................................. .......................................................................................................................................0.282 mm (0.011 in.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft - Removal Crankshaft: Service and Repair Crankshaft - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Remove the engine from the vehicle See: Service and Repair/Removal and Replacement/Engine - Removal 3. Remove the vibration damper (1) using crankshaft insert 8513A (2) and puller 1023 (3) See: Harmonic Balancer - Crankshaft Pulley/Service and Repair/Vibration Damper - Removal 4. Using the sequence shown, remove the flexplate bolts and remove the flexplate. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft - Removal > Page 2213 5. Using the sequence shown, remove the crankshaft rear oil seal retainer attaching bolts and remove the crankshaft rear oil seal retainer. 6. Using the sequence shown, remove the oil pan bolts and remove the oil pan See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan Removal 7. Remove the oil pump pickup tube (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft - Removal > Page 2214 NOTE: When the oil pan is removed, a new integral windage tray and gasket assembly must be installed. The old windage tray and gasket assembly cannot be reused. 8. Remove the windage tray/oil pan gasket. 9. Remove the timing chain cover See: Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Removal 10. Remove the oil pump (1) See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement 11. Remove the timing chain and sprockets See: Timing Components/Timing Chain/Service and Repair/Timing Chain & Sprockets - Removal NOTE: The connecting rods and bearing caps are not interchangeable and should be marked before removal to make sure they are installed in their original locations. CAUTION: Do not use a number stamp or a punch to mark the connecting rods or caps, as damage to the connecting rods could occur. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft - Removal > Page 2215 12. Mark the connecting rod and bearing cap positions using a permanent ink marker or scribe tool. 13. Remove the rod bearing caps and rod bearings See: Connecting Rod/Service and Repair/Removal and Replacement/Piston and Connecting Rod Removal NOTE: The main bearing caps are not interchangeable and should be marked before removal to make sure they are installed in their original locations. CAUTION: Do not use a number stamp or a punch to mark the main bearing caps, as damage to the main bearings could occur. 14. Mark the main bearing caps (1) using a permanent ink marker or scribe tool before removal. 15. Using the sequence shown, remove the main bearing cap bolts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft - Removal > Page 2216 16. Using the sequence shown, remove the main bearing cap cross bolts. 17. Remove the main bearing caps (1) and the main bearings one at a time. 18. Remove the thrust washers. 19. Lift the crankshaft out of the cylinder block. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft - Removal > Page 2217 Crankshaft: Service and Repair Crankshaft - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Select the proper main bearings See: Crankshaft Main Bearing/Service and Repair 2. Install the main bearings in the cylinder block (1). 3. Install the main bearing shells (2) in the bearing caps (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft - Removal > Page 2218 4. Lubricate the main bearing shells with clean engine oil. 5. Position the crankshaft (1) in the cylinder block. 6. Install the thrust washers (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft - Removal > Page 2219 7. Clean and oil all main bearing cap bolts. NOTE: The main bearing caps are not interchangeable, make sure they are installed in their original locations. 8. Install all main bearing caps (1) in their original location making sure the arrow (2) points toward the front of the engine. NOTE: The double ended oil pan stud must be installed in the same location from which it was removed. 9. Using the sequence shown, tighten the main bearing cap bolts to 13 Nm (10 ft. lbs.). 10. Using the sequence shown, tighten the main bearing cap bolts to 27 Nm (20 ft. lbs.). 11. Using the sequence shown, rotate the main cap bolts an additional 90°. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft - Removal > Page 2220 12. Install the cross bolts with new seal washers. 13. Using the sequence shown, tighten the cross bolts to 28 Nm (21 ft. lbs.). 14. Using the sequence shown, again tighten the cross bolts to 28 Nm (21 ft. lbs.). 15. Measure the crankshaft end play See: Crankshaft Main Bearing/Service and Repair 16. Position the connecting rods onto the crankshaft and install the rod bearing caps See: Connecting Rod/Service and Repair/Removal and Replacement/Piston and Connecting Rod - Installation 17. Install the timing chain and sprockets See: Timing Components/Timing Chain/Service and Repair/Timing Chain & Sprockets - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft - Removal > Page 2221 18. Install the oil pump See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement 19. Install the timing chain case cover See: Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Installation 20. Using the sequence shown, install the crankshaft rear oil seal retainer attaching bolts and tighten to 15 Nm (11 ft. lbs.).See: Crankshaft Seal Retainer/Service and Repair/Crankshaft Rear Oil Seal Retainer - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft - Removal > Page 2222 NOTE: When the oil pan is removed, a new integral windage tray and gasket assembly must be installed. The old gasket cannot be reused. 21. Install the new windage tray/oil pan gasket. 22. Install the oil pump pickup tube with a new O-ring and tighten bolt/nut (2) to 28 Nm (21 ft. lbs.). 23. Clean the oil pan gasket mating surface of the block and oil pan. NOTE: Mopar(R) Engine RTV must be applied to the 4 T-joints (1,2), (area where front cover, rear retainer, block, and oil pan gasket meet). The bead of RTV should cover the bottom of the gasket. This area is approximately 4.5 mm x 25 mm in each of the 4 T-joint locations. 24. Apply Mopar(R) Engine RTV at the 4 T- joints (1,2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft - Removal > Page 2223 25. Position the oil pan and install the mounting bolts and stud hand tight. 26. Using the sequence shown, tighten the bolts and stud to 12 Nm (9 ft. lbs.). 27. Position the flexplate on the crankshaft and install the retaining bolts hand tight. 28. Using the sequence shown, tighten the flexplate retaining bolts to 95 Nm (70 ft. lbs.). CAUTION: To prevent severe damage to the crankshaft, damper, and damper installer 8512A, thoroughly clean the damper bore and the crankshaft nose before installing damper. 29. Position the damper onto the crankshaft. 30. Assemble the damper installer 8512 (2) , and the pressing cup (1) from A/C hub installer 6871. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Service and Repair > Crankshaft - Removal > Page 2224 31. Using the damper installer 8512, and the pressing cup A/C hub installer 6871, press the damper onto the crankshaft. 32. Install the crankshaft damper bolt and tighten to 176 Nm (130 ft. lbs.). 33. Install the engine See: Service and Repair/Removal and Replacement/Engine Installation 34. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Engine Block Heater - Description Engine Block Heater: Description and Operation Engine Block Heater - Description ENGINE BLOCK HEATER WARNING: Do not operate engine unless block heater cord has been disconnected from power source and secured in place. The power cord must be secured in its retaining clips and routed away from exhaust manifolds and moving parts. The 3.7L/4.7L engine block heater is mounted in a core hole of the engine cylinder block (1) (in place of a freeze plug) with the heating element immersed in engine coolant. The power cord is attached to an engine compartment component with tie-straps. The 5.7L engine has the block heater located on the left side of the engine below the exhaust manifold in the rear of the engine (1) and is not immersed in the engine coolant but makes direct contact with the block. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Engine Block Heater - Description > Page 2229 Engine Block Heater: Description and Operation Engine Block Heater - Operation OPERATION The heater warms the engine coolant providing easier engine starting and faster warm-up in low temperatures. Connecting the power cord to a grounded 110-120 volt AC electrical outlet with a grounded three wire extension cord provides the electricity needed to heat the element. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Description and Operation > Page 2230 Engine Block Heater: Testing and Inspection BLOCK HEATER If the unit does not operate, possible causes can be either the power cord or the heater element. Test the power cord for continuity with a 110-volt voltmeter or110-volt test light. Test heater element continuity with an ohmmeter or a 12-volt test light. CAUTION: To prevent damage, the power cord must be secured in its retainer clips and away from any components that may cause abrasion or damage, such as linkages, exhaust components, etc. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater - Removal Engine Block Heater: Service and Repair Engine Block Heater - Removal 5.7L ENGINE 1. Raise and support the vehicle. 2. Remove the power cord from the block heater (1). 3. Remove the bolt (2) on the block heater (1). Remove the block heater assembly (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Engine Block Heater - Removal > Page 2233 Engine Block Heater: Service and Repair Engine Block Heater - Installation 5.7L ENGINE 1. Thoroughly clean the cylinder block core hole and the block heater seat. 2. Insert the block heater assembly (1) into the block. 3. With the block heater fully seated, tighten bolt (1) to 2 Nm (17 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications CRANKSHAFT PULLEY Vibration Damper Bolt.......................................................................................................................... ..................................................176 Nm (130 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Vibration Damper - Removal Harmonic Balancer - Crankshaft Pulley: Service and Repair Vibration Damper - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Power the vehicle down See: Starting and Charging/Battery/Testing and Inspection. 2. Remove water pump drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 3. Partially drain the cooling system See: Cooling System/Service and Repair. 4. Remove upper radiator hose. 5. Remove fan shroud . See: Cooling System/Radiator Cooling Fan 6. Remove crankshaft damper bolt. 7. Insert Crankshaft Insert 8513A (2) into the crankshaft. 8. Remove damper (1) using a Three Jaw Puller 1023 (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Service and Repair > Vibration Damper - Removal > Page 2239 Harmonic Balancer - Crankshaft Pulley: Service and Repair Vibration Damper - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions CAUTION: To prevent severe damage to the crankshaft, damper, and damper installer 8512A, thoroughly clean the damper bore and the crankshaft nose before installing damper. 1. Position damper onto crankshaft. 2. Assemble Damper Installer 8512 (2) , and the Pressing Cup (1) from A/C Hub Installer 6871. 3. Using Damper Installer 8512, and the pressing cup from A/C Hub Installer 6871, press damper onto crankshaft. 4. Install then tighten crankshaft damper bolt to 176 Nm (130 ft. lbs.). 5. Install cooling fan. 6. Install radiator upper shroud and tighten fasteners to 11 Nm (95 in. lbs.). 7. Install radiator upper hose. 8. Install water pump drive belt (1) See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. 9. Refill cooling system See: Cooling System/Service and Repair. 10. Power the vehicle up See: Starting and Charging/Battery/Testing and Inspection. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications PISTONS Measured at 38.0 mm (1.5 in.) Below Deck...................................................................................................................0.031 - 0.058 mm (0.012 - 0.023 in.) Weight..................................................................................................................... ...............................................................................413 grams ( 14.56 oz) Piston Length.................... .............................................................................................................................................................. .............53.3 mm (2.10 in.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 2243 Piston: Description and Operation DESCRIPTION CAUTION: Do not use a metal stamp to mark connecting rods as damage may result, instead use ink or a scratch awl. The pistons are made of a high strength aluminum alloy. Piston skirts are coated with a solid lubricant (Molykote(R)) to reduce friction and provide scuff resistance. The piston top ring groove and land is anodized. The connecting rods are made of forged powdered metal, with a fractured cap design. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures Piston: Procedures Piston and Connecting Rod - Cleaning CLEANING CAUTION: Do not use a wire wheel or other abrasive cleaning devise to clean the pistons or connecting rods. The pistons have a moly coating, this coating must not be damaged. 1. Using a suitable cleaning solvent, clean the pistons in warm water and towel dry. 2. Use a wood or plastic scraper to clean the ring land grooves. CAUTION: Do not remove the piston pin from the piston and connecting rod assembly. Piston and Connecting Rod - Inspection INSPECTION Check the connecting rod journal for excessive wear, taper and scoring.See: Connecting Rod/Service and Repair/Procedures. Check the connecting rod for signs of twist or bending. Check the piston for taper and elliptical shape before it is fitted into the cylinder bore. See: Connecting Rod/Service and Repair/Procedures. Check the piston for scoring or scraping marks in the piston skirts. Check the ring lands for cracks and/or deterioration. Piston Fitting PISTON FITTING 1. To correctly select the proper size piston, a cylinder bore gauge (2), capable of reading in 0.003 mm (0.0001 in.) INCREMENTS is required. If a bore gauge is not available, do not use an inside micrometer. 2. Measure the inside diameter of the cylinder bore at a point 38.0 mm (1.5 inches) below top of bore (4). Start perpendicular (across or at 90 degrees) to the axis of the crankshaft at point A (1) and then take an additional bore reading 90 degrees to that at point B (1). 3. The coated pistons will be serviced with the piston pin and connecting rod pre-assembled. The piston-rod assembly is specific for the left cylinder bank (odd numbered) and the right cylinder bank (even numbered) and must not be interchanged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2246 4. Measure the piston diameter with a micrometer at points (1,2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2247 Piston: Removal and Replacement Piston and Connecting Rod - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Using the sequence shown, remove the oil pan bolts and remove the oil pan and gasket/windage tray See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Removal 3. Remove the cylinder heads See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Removal 4. If necessary, remove the ridge from the top of the cylinder bores with a reliable ridge reamer before removing the pistons from the cylinder block. Be sure to keep the tops of the pistons covered during this operation. NOTE: When removing the piston and connecting rod assemblies from the engine, rotate the crankshaft until each connecting rod is centered in the cylinder bore. CAUTION: Do not use a number stamp or a punch to mark the connecting rods or caps, as damage to the connecting rods could occur. NOTE: The connecting rods and bearing caps are not interchangeable and should be marked before removal to make sure they are installed in their original locations. 5. Mark connecting rod and bearing cap positions using a permanent ink marker or scribe tool. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2248 CAUTION: Care must be taken not to damage the fractured rod and cap joint face surfaces, as engine damage may occur. CAUTION: Care must be taken not to nick crankshaft journals, as engine damage may occur. 6. Remove the connecting rod cap and install the connecting rod guides 8507 (1) into the connecting rod being removed. Remove the piston from the cylinder bore. Repeat this procedure for each piston being removed. 7. Immediately after rod removal, install the bearing cap on the connecting rod to prevent damage to the fractured cap and rod surfaces. 8. Remove the piston rings from the piston(s). Piston and Connecting Rod - Installation INSTALLATION NOTE: Before reinstalling used rings or installing new rings, the ring clearances must be checked. 1. Check piston ring clearance See: Piston Ring/Service and Repair NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs. 2. Install the piston rings onto the pistons See: Piston Ring/Service and Repair 3. Immerse the piston head and rings in clean engine oil. Position a ring compressor over the piston and rings. Tighten the piston ring compressor. Make sure the piston ring position does not change during this procedure. 4. Position the bearing (1) onto the connecting rod. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2249 5. Install special tool 8507 connecting rod guides (1) onto the connecting rod bolt threads. 6. Lubricate the bearing surface with clean engine oil. 7. The pistons are marked by an arrow on the top of the piston indicating installation position. This mark must be pointing toward the front of the engine on both cylinder banks. 8. Wipe the cylinder bore clean and lubricate with clean engine oil. 9. Rotate the crankshaft until the connecting rod journal is centered with the cylinder bore. Insert the piston and rod assembly into the cylinder bore and carefully position the connecting rod guides over the crankshaft journal. 10. Tap the piston down into the cylinder bore using a hammer handle while guiding the connecting rod into position on the rod journal. CAUTION: The connecting rod bolts must not be reused. Always replace the connecting rod bolts whenever they are loosened or removed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Procedures > Page 2250 11. Wipe the connecting rod cap (1) clean and lubricate with clean engine oil and install the bearing (3). 12. Remove special tool 8507 connecting rod guides. NOTE: The connecting rods and bearing caps are not interchangeable, line up the previously marked bearing caps and connecting rods to ensure assembly to their original location. 13. Lubricate the bearing surfaces with clean engine oil and position the rod cap in place. 14. Lubricate the new rod bolts with clean engine oil. 15. Install the new and lubricated rod bolts and tighten to 21 Nm (15 ft. lbs.) plus a 90° turn. 16. Install the cylinder head(s) See: Cylinder Head Assembly/Service and Repair/Removal and Replacement/Cylinder Head - Installation 17. Install the timing chain cover See: Timing Components/Timing Cover/Service and Repair/Engine Timing Cover(s) - Installation 18. Install the cylinder head covers See: Cylinder Head Assembly/Valve Cover/Service and Repair/Cylinder Head Cover(s) - Installation 19. Install the intake manifold See: Intake Manifold/Service and Repair/Removal and Replacement/Intake Manifold - Installation 20. Install the new oil pan gasket/windage tray and oil pan See: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Installation 21. Fill the engine with oil See: Engine Lubrication/Engine Oil/Service and Repair Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications PISTON RINGS Ring Groove Diameter Top Groove...................................................................................................... .......................................................................90.4 - 90.6 mm (3.56 - 3.57 in.) Second Groove........... ............................................................................................................................................................. 88.4 - 88.7 mm (3.48 - 3.49 in.) Ring Gap Top Compression Ring......................................................................................................... ..............................................0.40 - 0.55 mm (0.015 - 0.021 in.) Second Compression Ring.............. ....................................................................................................................................0.24 - 0.51 mm (0.009 - 0.020 in.) Oil Control Rails...................................................................................................... .......................................................0.15 - 0.66 mm (0.0059 - 0.0259 in.) Side Clearance Top Compression Ring............................................................................................... ......................................................0.04 - 0.09 mm (0.001 - 0.0035 in.) Second Compression Ring.... ............................................................................................................................................0.04 - 0.08 mm (0.001 - 0.0031 in.) Oil Control Rails............................................................................................. ....................................................................0.06 - 0.21 mm (0.002 - 0.008 in.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 2254 Piston Ring: Service and Repair PISTON RING FITTING PISTON RING END GAP NOTE: Before reinstalling used rings or installing new rings, the ring clearances must be checked. 1. Wipe the cylinder bore clean. 2. Insert the ring in the cylinder bore. NOTE: The ring gap measurement must be made with the ring positioned at least 12 mm (0.50 inch.) from bottom of cylinder bore. 3. Using a piston, to ensure that the ring is squared in the cylinder bore, slide the ring downward into the cylinder. 4. Using a feeler gauge check the ring end gap. Replace any rings not within specification. PISTON RING SIDE CLEARANCE NOTE: Make sure the piston ring grooves are clean and free of nicks and burrs. 1. Measure the ring side clearance as shown make sure the feeler gauge (1) fits snugly between the ring land and the ring. Replace any ring not within specification. 2. Rotate the ring around the piston, the ring must rotate in the groove with out binding. PISTON RING SPECIFICATION CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 2255 PISTON RING INSTALLATION NOTE: The No. 1 and No. 2 piston rings have a different cross section. Ensure No. 2 ring is installed with manufacturers I.D. mark (Dot) facing up, towards top of the piston. NOTE: Piston rings are installed in the following order: - Oil ring expander. - Lower oil ring side rail. - Upper oil ring side rail. - No. 2 Intermediate piston ring. - No. 1 Upper piston ring. 1. Install the oil ring expander. 2. Install upper side rail by placing one end between the piston ring groove and the expander ring. Hold end firmly and press down the portion to be installed until side rail is in position. Repeat this step for the lower side rail. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications > Page 2256 3. Install No. 2 intermediate piston ring using a piston ring installer. 4. Install No. 1 upper piston ring using a piston ring installer. NOTE: Install the piston rings so the gaps positioned as indicated with the piston viewed from the top. NOTE: Staggering ring gap is important for oil control. 5. Install the oil expander so the ring gap is located in the (1) position. 6. Install the oil ring rails so the ring gap is located in the (2,4) position. 7. Install the second compression ring so the ring gap is located in the (3) position. 8. Install the top compression so the ring gap is located in the (1) position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions Use the following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove the fuel fill cap. 2. Remove the fuel pump relay or the fuel pump speed relay from the Power Distribution Center (PDC) (1), refer to the label on the underside of the PDC cover for relay locations or See: Maintenance/Fuses and Circuit Breakers/Fuse/Locations/Fuse Panel 3. Start and run the engine until it stalls. 4. Attempt restarting the engine until it will no longer run. 5. Turn the ignition key to the OFF position. 6. Disconnect the 12 volt battery system ground isolation connector (1). 7. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down NOTE: Excessive fuel spillage onto the gaskets can cause gaskets to expand and dislodge from gasket groove. 8. Place a rag or towel around the fuel line quick-connect fitting at the fuel rail to prevent residual fuel spray or spillage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Page 2261 9. Disconnect the fuel supply line quick connect fitting at the fuel rail (1) and plug the fuel supply line with a shipping cap See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair 10. Return the fuel pump relay or the fuel pump speed relay to the PDC. NOTE: One or more Diagnostic Trouble Code(s) (DTC) may have been stored in the PCM memory due to the fuel pump relay removal. A diagnostic scan tool must be used to erase a DTC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Valve Rocker Arm - Removal Rocker Arm Assembly: Service and Repair Valve Rocker Arm - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Remove the ignition coils (1) See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil - Removal 3. Remove the cylinder head cover See: Valve Cover/Service and Repair/Cylinder Head Cover(s) Removal Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Valve Rocker Arm - Removal > Page 2266 4. Install the pushrod retainer (1) 9070. 5. Using the sequence shown, remove the rocker shafts assembly retaining bolts. CAUTION: The rocker shaft assemblies are not interchangeable between the intake and the exhaust, failure to install them in the correct location could result in engine damage. The intake rocker arms (1) are marked with the letter "I" (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Valve Rocker Arm - Removal > Page 2267 CAUTION: Do not remove the retainers (1) from the rocker shaft (3). 6. Remove the rocker shaft assembly (3). Note the rocker shaft location during removal. CAUTION: The longer pushrods are for the exhaust side and the shorter pushrods are for the intake side. 7. Remove the pushrods. Note the pushrod location during removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Valve Rocker Arm - Removal > Page 2268 Rocker Arm Assembly: Service and Repair Valve Rocker Arm - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions CAUTION: The longer pushrods are for the exhaust side and the shorter pushrods are for the intake side. 1. Install the pushrods in the same order as removed. 2. Install the pushrod retainer (1) 9070. CAUTION: Make sure that the retainers (1) and the rocker arms (2) are not overlapped when tightening bolts or engine damage could result. CAUTION: Due to the changes in the pushrod clearance holes in the Eagle 5.7L cylinder heads, close attention must be given when installing the pushrod(s) into the tappet(s). Once the pushrod(s) have been installed, use a suitable light to look down through the pushrod hole(s). This will allow you to verify the pushrod(s) are centered properly in the tappet(s) and avoid engine damage. Recheck after the rocker shaft assembly has been installed and tightened to specification. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Valve Rocker Arm - Removal > Page 2269 CAUTION: The rocker shaft assemblies are not interchangeable between the intake and the exhaust, failure to install them in the correct location could result in engine damage. The intake rocker arms (1) are marked with the letter "I" (2). 3. Install the rocker shaft assemblies in the same order as removed. 4. Using the sequence shown, tighten the rocker shaft bolts to 22 Nm (16 ft. lbs.). CAUTION: Do Not rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about five minutes). 5. Remove the pushrod retainer (1) 9070. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Valve Rocker Arm - Removal > Page 2270 6. Install the cylinder head cover See: Valve Cover/Service and Repair/Cylinder Head Cover(s) Installation 7. Install the ignition coils (1) See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil - Removal 8. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 9. Start the engine and inspect for leaks. 10. Road test the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal Valve Cover: Service and Repair Cylinder Head Cover(s) - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the fuel system pressure release procedure See: Fuel Pressure Release/Service and Repair 2. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 3. Disconnect the 12 volt battery system ground isolation connector (1) located next to the electric vacuum pump (2). 4. Disconnect the High Voltage Inter Lock (HVIL) electrical connector (1). 5. Remove the clean air tube retaining bolt (3). 6. Remove the clean air tube (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal > Page 2275 7. Remove the center air cleaner housing trim cover (2) with a small screwdriver (1). 8. Disconnect the Intake Air Temperature (IAT) sensor electrical connector (1). 9. Remove the center air cleaner housing retaining bolt (2). 10. Slightly raise the front of the air cleaner housing (3) up off the throttle body. 11. Slide the air cleaner housing forward to remove the rear air cleaner housing pegs (2) from the grommets (1) on the rear of the intake manifold. 12. Remove the air cleaner housing from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal > Page 2276 13. For right side cylinder head cover removal, remove the Traction Power Inverter Module (TPIM) (1) See: Hybrid Drive Systems/Power Control System/Voltage Inverter/Service and Repair/Traction Power Inverter Module - Removal 14. Disconnect the ignition coil connectors (1). 15. Remove the ignition coil retaining bolts (3). 16. Remove the ignition coils (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal > Page 2277 17. Using the sequence shown, remove the cylinder head cover retaining bolts. 18. Remove the cylinder head cover (1). NOTE: The gasket (2) may be used again, provided no cuts, tears, or deformation have occurred. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal > Page 2278 Valve Cover: Service and Repair Cylinder Head Cover(s) - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur. CAUTION: Do not allow other components including the wire harness to rest on or against the engine cylinder head cover. Prolonged contact with other objects may wear a hole in the cylinder head cover. 1. Clean the cylinder head cover (1) and both sealing surfaces (4), inspect and replace the gasket (2) as necessary. 2. Install the cylinder head cover and hand start all fasteners. Verify that all double ended studs (3) are in the correct location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal > Page 2279 3. Using the sequence shown, tighten the cylinder head cover retaining bolts to 8 Nm (71 lbs in.). 4. Before installing the ignition coils, apply dielectric grease to the inside of the spark plug boots (1). 5. Install the ignition coils (1). 6. Tighten the ignition coil retaining bolts (3) to 7 Nm (62 in. lbs.). 7. Connect the ignition coil electrical connectors (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal > Page 2280 8. If removed, Install the Traction Power Inverter Module (TPIM) (1) See: Hybrid Drive Systems/Power Control System/Voltage Inverter/Service and Repair/Traction Power Inverter Module - Installation 9. Verify the throttle body seal is properly aligned at the bottom of the air cleaner housing. 10. Slide the rear air cleaner housing pegs (2) into the grommets (1) on the rear of the intake manifold and lower the front of the air cleaner housing onto the throttle body. NOTE: Verify the air cleaner housing (3) is installed properly in the rear grommets by reaching around the left rear corner of the air cleaner and feeling for the pegs protruding through the rubber grommets. If the plastic pegs cannot be felt, the air cleaner will need to be reinstalled. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Cylinder Head Cover(s) - Removal > Page 2281 11. Install the air cleaner housing center retaining bolt (2) and tighten to 7 Nm (62 in. lbs.). 12. Connect the intake air temperature (IAT) sensor electrical connector (1). 13. Install the center air cleaner housing trim cover (2). 14. Install the clean air tube (2). 15. Install the clean air tube fastener (3) and tighten to 7 Nm (62 in. lbs.). 16. Connect the High Voltage Inter Lock (HVIL) electrical connector (1). 17. Connect the 12 volt battery system ground isolation connector (1) located next to the electric vacuum pump (2). 18. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Springs - Removal Valve Spring: Service and Repair Valve Springs - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the 12 volt battery system ground isolation connector (1) located next to the electric vacuum pump (2). 3. Remove the clean air tube fastener (3). 4. Disconnect the High Voltage Inter Lock (HVIL) electrical connector (1). 5. Remove the air cleaner assembly See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body Removal Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Springs - Removal > Page 2286 6. For removal of the right side cylinder head cover, remove the Traction Power Inverter Module (TPIM) (1) See: Hybrid Drive Systems/Power Control System/Voltage Inverter/Service and Repair/Traction Power Inverter Module - Removal 7. Remove the ignition coil electrical connectors (1). 8. Remove the ignition coils (2). 9. Remove the spark plugs. 10. Using the sequence shown, remove the cylinder head cover retaining bolts and remove the cylinder head cover See: Valve Cover/Service and Repair/Cylinder Head Cover(s) - Removal Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Springs - Removal > Page 2287 CAUTION: The rocker shaft assemblies are not interchangeable between the intake and the exhaust, failure to install them in the correct location could result in engine damage. The intake rocker arms (1) are marked with the letter "I" (2). CAUTION: The piston must be at TDC and both valves closed on the cylinder to be serviced. CAUTION: The longer pushrods are for the exhaust side and the shorter pushrods are for the intake side. NOTE: Pushrods must be installed in the same order as removed. 11. If removing the intake valve spring, install the pushrod retainer 9070 (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Springs - Removal > Page 2288 12. Using the sequence shown, remove the exhaust/intake rocker arm shaft retaining bolts. NOTE: Tap the top of the valve spring retainer to loosen the spring retainers locks. 13. Install the rocker arm valve spring compressor shaft 9065A (1). 14. If needed, Install the spring compressor adapter arm 9065A. 15. Insert an air hose (2) into the spark plug hole and charge the cylinder with air. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Springs - Removal > Page 2289 NOTE: Tap the top of the valve spring retainer to loosen the spring retainers locks. 16. Using the valve spring compressor 9065A (1), compress the valve spring and remove the valve retainer locks. 17. Release the spring compressor and remove valve spring. NOTE: The valve springs are interchangeable between intake and exhaust. 18. Remove the valve seal. NOTE: All valve springs and seals are removed in the same manner. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Springs - Removal > Page 2290 Valve Spring: Service and Repair Valve Springs - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Install the valve seal. 2. Install the valve spring. 3. Using the valve spring compressor 9065A (1), compress the valve spring and install the valve spring retainer and locks. 4. Remove the spring compressor. 5. Remove the air hose from the spark plug hole. NOTE: All valve springs and seals are installed in the same manner. CAUTION: The rocker shaft assemblies are not interchangeable between the intake and the exhaust, failure to install them in the correct location could result in engine damage. The intake rocker arms (1) are marked with the letter "I" (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Springs - Removal > Page 2291 CAUTION: Make sure that the retainers (1) and the rocker arms (2) are not overlapped when tightening bolts or engine damage could result. CAUTION: Due to the changes in the pushrod clearance holes in the Eagle 5.7L cylinder heads, close attention must be given when installing the pushrod(s) into the tappet(s). Once the pushrod(s) have been installed, use a suitable light to look down through the pushrod hole(s). This will allow you to verify the pushrod(s) are centered properly in the tappet(s) and avoid engine damage. Recheck after the rocker shaft assembly has been installed and tightened to specification. CAUTION: The longer pushrods are for the exhaust side and the shorter pushrods are for the intake side. NOTE: Pushrods must be installed in the same order as removed. 6. Install the rocker arm shaft and pushrods See: Rocker Arm Assembly/Service and Repair/Valve Rocker Arm - Installation 7. Using the sequence shown, tighten the rocker shaft bolts to 22 Nm (16 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Springs - Removal > Page 2292 8. If used, remove the pushrod retainer 9070 (1). CAUTION: Do not use harsh cleaners to clean the cylinder head covers. Severe damage to covers may occur. CAUTION: Do not allow other components including the wire harness to rest on or against the engine cylinder head cover. Prolonged contact with other objects may wear a hole in the cylinder head cover. 9. Clean the cylinder head cover and both sealing surfaces, inspect and replace the gasket as necessary. 10. Install the cylinder head cover and hand start all fasteners. Verify that all double ended studs are in the correct location. 11. Using the sequence shown, tighten the cylinder head cover retaining bolts to 8 Nm (71 in. lbs.). 12. Install the spark plugs. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Springs - Removal > Page 2293 13. Before installing the ignition coils, apply dielectric grease to the inside of the spark plug boots. 14. Install the ignition coil (2) on the plugs and tighten the fasteners (3) to 7 Nm (62 in. lbs). 15. Connect the ignition coil electrical connectors (1). 16. If removed, Install the Traction Power Inverter Module (TPIM) (1) See: Hybrid Drive Systems/Power Control System/Voltage Inverter/Service and Repair/Traction Power Inverter Module - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Valve Springs - Removal > Page 2294 17. Install the air cleaner assembly See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body Installation 18. Install the clean air tube fastener (3) and tighten to 7 Nm (62 in. lbs.). 19. Connect the High Voltage Inter Lock (HVIL) electrical connector (1). 20. Connect the 12 volt battery system ground isolation connector (1) located next to the electric vacuum pump (2). 21. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation > Intake and Exhaust Valves - Description Valve: Description and Operation Intake and Exhaust Valves - Description VALVES Both the intake and the exhaust valves are made of steel. The intake valve is 50.93 mm (2.00 inches) in diameter and the exhaust valve is 39.53 mm (1.55 inches) in diameter. All valves use three-bead lock keepers to retain the springs and promote valve rotation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Description and Operation > Intake and Exhaust Valves - Description > Page 2299 Valve: Description and Operation Intake and Exhaust Valve Guides - Description VALVE GUIDES The valve guides are made of powdered metal and pressed into the cylinder head. The guides are not replaceable or serviceable, and valve guide reaming is not recommended. If the guides are worn beyond acceptable limits, replace the cylinder heads. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Procedures Valve: Procedures REFACING VALVE FACE AND VALVE SEAT ANGLE CHART NOTE: Valve seats that are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise the cylinder head must be replaced. NOTE: When refacing valves and valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. 1. Using a suitable dial indicator, measure the center of the valve seat. Total run out must not exceed 0.051 mm (0.002 in). 2. Apply a small amount of Prussian Blue to the valve seat. Insert the valve into the cylinder head. Rotate valve while applying light pressure on the valve seat. Remove the valve and examine the valve face. If the blue is transferred below the top edge of the valve face, lower the valve seat using a 15 degree stone. If the blue is transferred to the bottom edge of the valve face, raise the valve seat using a 65 degree stone. 3. When the seat is properly positioned the width of the intake seat must be 1.18 - 1.62 mm (0.0464 - 0.0637 in.) and the exhaust seat must be 1.48 1.92 mm (0.058 - 0.075 in.). 4. Check the valve spring installed height after refacing the valve and seat. The installed height for both intake and exhaust valve springs must not exceed 46.0 mm (1.81 in.). 5. The valve seat must maintain a seat angle of 44 1/2° - 45°. 6. The valve face must maintain a face angle of 45° - 45 1/2°. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Service and Repair > Procedures > Page 2302 Valve: Removal and Replacement Intake and Exhaust Valves - Removal REMOVAL 1. Remove the cylinder head See: Service and Repair/Removal and Replacement/Cylinder Head Removal. 2. Compress valve springs using valve spring compressor tool C-3422-D and adapter 8464. 3. Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. 4. Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location. Intake and Exhaust Valves - Installation INSTALLATION 1. Clean the valves thoroughly. Discard burned, warped and cracked valves. 2. Remove the carbon and varnish deposits from inside of the valve guides with a reliable guide cleaner. 3. Measure the valve stems for wear. If wear exceeds 0.051 mm (0.002 inch), replace the valve. 4. Coat the valve stems with lubrication oil and insert them into the cylinder head. 5. If the valves or seats are reground, check the valve stem height. If the valve is too long, replace the cylinder head. 6. Install new seals on all valve guides. Install the valve springs and valve retainers. 7. Compress the valve springs with valve spring compressor tool C- 3422 and adapter 8464, install locks and release tool. If valves and/or seats are ground, measure the installed height of the springs. Make sure the measurement is taken from the bottom of spring seat in the cylinder head to the bottom surface of the spring retainer. 8. Install the cylinder head See: Service and Repair/Removal and Replacement/Cylinder Head Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation Drive Belt: Description and Operation ACCESSORY DRIVE BELT The accessory drive belt is a serpentine type belt. Satisfactory performance of these belts depends on belt condition and proper belt tension. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 2307 Drive Belt: Testing and Inspection ACCESSORY DRIVE BELT VISUAL DIAGNOSIS When diagnosing the accessory drive belt, small cracks that run across the ribbed surface of the belt from rib to rib, are considered normal. These are not a reason to replace the belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing. Refer toACCESSORY DRIVE BELT DIAGNOSIS CHART for further belt diagnosis. NOISE DIAGNOSIS Noises generated by the accessory drive belt are most noticeable at idle. Before replacing a belt to resolve a noise condition, inspect all of the accessory drive pulleys for alignment, glazing, or excessive end play. ACCESSORY DRIVE BELT DIAGNOSIS CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 2308 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Description and Operation > Page 2309 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures Drive Belt: Procedures CLEANING Clean all foreign debris from belt pulley grooves. The belt pulleys must be free of oil, grease and coolants before installing the drive belt. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > Procedures > Page 2312 Drive Belt: Removal and Replacement Serpentine Accessory Drive Belt - Removal 5.7L HEV ENGINE 1. Raise and support the vehicle. 2. Using hand tools (3) , rotate the crankshaft clockwise, walking the water pump drive belt (2) off of the crankshaft pulley (1). Serpentine Accessory Drive Belt - Installation 5.7L HEV ENGINE 1. Position the drive belt (1) onto the crankshaft pulley (1). Make sure the belt is fully seated in the grooves. 2. Start the drive belt (1) onto the water pump pulley. 3. Working from the back side of the water pulley, insert a nylon wire tie, 196.85X3.175X1.27mm (7.75X0.125x0.050 in.), through one of the holes in the pulley. CAUTION: Do not use a wire tie with a metal locking tab. 4. Tighten the wire tie to hold the drive belt in position. 5. While holding the drive belt to make sure it stays in position, using a ratchet and socket (3), slowly rotate the engine clockwise. 6. Once the belt is in position on the pulley, continue rotating the engine until the wire tie snaps. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation > Accessory Drive Belt Tensioner - Description Drive Belt Tensioner: Description and Operation Accessory Drive Belt Tensioner - Description BELT TENSIONER Correct accessory drive belt tension is required to ensure optimum performance of the belt driven engine accessories. If the specified tension is not maintained, accessory drive belt slippage may cause; engine overheating, lack of power steering assist, loss of air conditioning capacity, reduced generator output rate, and greatly reduced belt life. It is not necessary to adjust belt tension, all engines are equipped with an accessory drive belt tensioner (1). The tensioner maintains correct belt tension at all times. Due to use of this accessory drive belt tensioner, do not attempt to use a belt tension gauge to check belt tension. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Description and Operation > Accessory Drive Belt Tensioner - Description > Page 2317 Drive Belt Tensioner: Description and Operation Accessory Drive Belt Tensioner - Operation ACCESSORY DRIVE BELT The accessory drive belt tensioner maintains belt tension by using internal spring pressure, a pivoting arm and a pulley to press against the drive belt. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Accessory Drive Belt Tensioner - Removal Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner - Removal 5.7L ENGINE 1. Remove the accessory drive belt See: Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 2. Remove the tensioner (1) and the mounting bracket bolt (2) from the engine block. 3. Remove the tensioner assembly (1) from the mounting bracket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Service and Repair > Accessory Drive Belt Tensioner - Removal > Page 2320 Drive Belt Tensioner: Service and Repair Accessory Drive Belt Tensioner - Installation 5.7L ENGINE 1. Install the accessory drive belt tensioner (1) on to the mounting bracket. Tighten the bolt to 61 Nm (45 ft. lbs.). 2. Install accessory drive belt tensioner (1) and bracket assembly to the engine block. Tighten the bolt (2) to 41 Nm (30 ft. lbs.). 3. Install the accessory drive belt See: Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal Engine Mount: Service and Repair Engine Mount Insulator - Removal Rear REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Raise and support the vehicle. 3. Using a suitable jack, support the transmission. 4. Remove the transmission mount to crossmember nuts (3). 5. Remove the transmission to mount bolts (4). 6. Raise the transmission enough to remove the rear transmission mount (1). 7. Remove the mount (1). Front REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2325 2. Support the engine using engine support fixture 8534B (1). 3. Raise and support the vehicle. 4. Remove the skid plate, if equipped. 5. Remove the support crossmember bolts (1) and remove crossmember (2). 6. Remove the engine oil filter. 7. Support the front axle with a suitable jack. 8. Remove the two bolts (1) securing the differential housing (3) to the left engine mount. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2326 9. Remove the three bolts (2) securing the axle to the left engine bracket. 10. Remove the two bolts (2) securing the axle tube (1) to the right engine mount. 11. Lower the front axle. 12. Remove the right and left engine front mount through bolts (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2327 13. Raise the engine and remove the right and left engine mount bolts (2). 14. Remove the right and left engine mounts (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2328 Engine Mount: Service and Repair Engine Mount Insulator - Installation Rear INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions NOTE: Mopar(R) Lock & Seal Adhesive must be applied to the bolts before installation. 1. Apply Mopar(R) Lock & Seal Adhesive to the transmission mount bolts. 2. Install the bolts that attach the transmission mount to the transmission bracket (4) and tighten to 61 Nm (45 ft. lbs.). 3. Lower the transmission so the transmission mount (1) rests on the crossmember (2), and the studs of the transmission mount are aligned in the slots in the crossmember. 4. Install the nuts (3) onto the transmission mount studs and tighten to 54 Nm (40 ft. lbs.). 5. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Front INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions NOTE: For mount to engine block and left engine bracket to front axle bolts, apply Mopar(R) Lock & Seal Adhesive, Medium Strength Thread-locker. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2329 1. Install the right and left engine mounts (1) and tighten bolts (2) to 95 Nm (70 ft. lbs.). 2. Raise the front axle into the frame and install the two bolts (2) securing the axle tube (1) to the right engine mount hand tight. 3. Install the three bolts (2) securing the axle to the left engine bracket hand tight. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2330 4. Install the two bolts (1) securing the differential housing (3) to the left engine mount hand tight. 5. Tighten all axle bolts to 95 Nm (70 ft. lbs.). 6. Install the engine oil filter. 7. Install the skid plate, if equipped. 8. Install the support crossmember (2) and securely tighten bolts (1). 9. Lower the vehicle. 10. Lower the engine using engine support fixture 8534B (1) until the left and right engine mounts align with the engine bracket through holes. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Insulator - Removal > Page 2331 11. Install the right and left engine mount through bolts (3) and tighten to 95 Nm (70 ft. lbs.). 12. Remove the engine support fixture 8534B. 13. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE At Curb Idle Speed (MIN)*.................................................................................................................... ............................................................25 kPa (4 psi) At 3000 rpm....................................................... ..........................................................................................................................170 - 758 kPa (25 110 psi) CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 2336 Engine Oil Pressure: Testing and Inspection CHECKING ENGINE OIL PRESSURE 1. Remove the oil pressure sending unit and install gauge assembly C-3292A. 2. Run the engine until thermostat opens. 3. Oil Pressure: - Curb Idle-25 kPa (4 psi) minimum - 3000 rpm-170 - 758 kPa (25 - 110 psi) 4. If oil pressure is 0 at idle, shut off engine. Check for a clogged oil pick-up screen or a pressure relief valve stuck open. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Engine Oil: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2341 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil (with filter) .......................................................................................................................... ............................................................. 6.6L (7.0 Qt) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2344 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................................... SAE 5W-20 API Certified, meeting material standard MS-6395 or equivalent Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2345 Engine Oil: Description and Operation ENGINE OIL WARNING: New or used engine oil can be irritating to the skin. Avoid prolonged or repeated skin contact with engine oil. Contaminants in used engine oil, caused by internal combustion, can be hazardous to your health. Thoroughly wash exposed skin with soap and water. Do not wash skin with gasoline, diesel fuel, thinner, or solvents, health problems can result. Do not pollute, dispose of used engine oil properly. Contact your dealer or government agency for location of collection center in your area. When service is required, Chrysler Corporation recommends that only Mopar(R) brand parts, lubricants and chemicals be used. Mopar(R) provides the best engineered products for servicing Chrysler Corporation vehicles. Only lubricants bearing designations defined by the following organization should be used. - Society of Automotive Engineers (SAE) - American Petroleum Institute (API) - National Lubricating Grease Institute (NLGI) - Association des Constructeurs Europeens d' Automobiles (European Automobile Manufacturers Association) (ACEA) API SERVICE GRADE CERTIFIED Use an engine oil that is API Certified. MOPAR(R) provides engine oils, that meet or exceed this requirement. SAE VISCOSITY An SAE viscosity grade is used to specify the viscosity of engine oil. Use only engine oils with multiple viscosities. These are specified with a dual SAE viscosity grade which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited to your particular temperature range and variation. Refer to the engine oil filler cap for the recommend engine oil viscosity for each vehicle. ACEA Categories For countries that use the ACEA European Oil Categories for Service Fill Oils, use engine oils that meet the requirements of ACEA A1/B1, A2/B2, or A3/B3. ENERGY CONSERVING OIL An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CONSERVING is located on the label of an engine oil container. CONTAINER IDENTIFICATION Standard engine oil identification notations have been adopted to aid in the proper selection of engine oil. The identifying notations are located on the front label of engine oil plastic bottles and the top of engine oil cans. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2346 This symbol means that the oil has been certified by the American Petroleum Institute (API). DaimlerChrysler only recommend API Certified engine oils. Use Mopar(R) engine oil or equivalent. SYNTHETIC ENGINE OILS There are a number of engine oils being promoted as either synthetic or semi-synthetic. If you chose to use such a product, use only those oils that meet the American Petroleum Institute (API) and SAE viscosity standard. Follow the service schedule that describes your driving type. ENGINE OIL ADDITIVES/SUPPLEMENTS The manufacturer does not recommend the addition of any engine oil additives/supplements to the specified engine oil. Engine oil additives/supplements should not be used to enhance engine oil performance. Engine oil additives/supplements should not be used to extend engine oil change intervals. No additive is known to be safe for engine durability and can degrade emission components. Additives can contain undesirable materials that harm the long term durability of engines by: - Doubling the level of phosphorus in the engine oil. The ILSAC (International Lubricant Standard Approval Committee) GF-2 and GF-3 standards require that engine oil contain no more than 0.10% phosphorus to protect the vehicles emissions performance. Addition of engine oil additives/supplements can poison, from the added sulfur and phosphorus, catalysts and hinder efforts to guarantee emissions performance to 80,000 miles. - Altering the viscosity characteristics of the engine oil so that it no longer meets the requirements of the specified viscosity grade. - Creating potential for an undesirable additive compatibility interaction in the engine crankcase. Generally it is not desirable to mix additive packages from different suppliers in the crankcase; there have been reports of low temperature engine failures caused by additive package incompatibility with such mixtures. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2347 Engine Oil: Service and Repair ENGINE OIL SERVICE The engine oil level indicator is located at the left hand of the engine on the 5.7L engines. CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result. Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about ten minutes before checking oil level. Checking engine oil level on a cold engine is not accurate. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately five minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the ADD mark on dipstick. ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance SchedulesSee: Maintenance. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged. 6. Install drain plug in crankcase. Torque to 34 Nm ( 25 ft. lbs.). 7. Lower vehicle and fill crankcase with specified type and amount of engine oil described. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. NOTE: Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING at beginning of this section. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Procedures Oil Filter: Procedures ENGINE OIL SERVICE The engine oil level indicator is located at the left hand of the engine on the 5.7L engines. CRANKCASE OIL LEVEL INSPECTION CAUTION: Do not overfill crankcase with engine oil, pressure loss or oil foaming can result. Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about ten minutes before checking oil level. Checking engine oil level on a cold engine is not accurate. To ensure proper lubrication of an engine, the engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick. 1. Position vehicle on level surface. 2. With engine OFF, allow approximately five minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. 3. Wipe dipstick clean. 4. Install dipstick and verify it is seated in the tube. 5. Remove dipstick, with handle held above the tip, take oil level reading. 6. Add oil only if level is below the ADD mark on dipstick. ENGINE OIL CHANGE Change engine oil at mileage and time intervals described in Maintenance SchedulesSee: Maintenance. Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug if damaged. 6. Install drain plug in crankcase. Torque to 34 Nm ( 25 ft. lbs.). 7. Lower vehicle and fill crankcase with specified type and amount of engine oil described. 8. Install oil fill cap. 9. Start engine and inspect for leaks. 10. Stop engine and inspect oil level. NOTE: Care should be exercised when disposing used engine oil after it has been drained from a vehicle engine. Refer to the WARNING at beginning of this section. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Service and Repair > Procedures > Page 2352 Oil Filter: Removal and Replacement Engine Oil Filter - Removal REMOVAL All engines are equipped with a high quality full-flow, disposable type oil filter. Chrysler Corporation recommends a Mopar(R) or equivalent oil filter be used. 1. Position a drain pan under the oil filter. 2. Using a suitable oil filter wrench loosen filter. 3. Rotate the oil filter counterclockwise to remove it from the cylinder block oil filter boss. 4. When filter separates from cylinder block oil filter boss, tip gasket end upward to minimize oil spill. Remove filter from vehicle. NOTE: Make sure filter gasket was removed with filter. 5. With a wiping cloth, clean the gasket sealing surface of oil and grime. Engine Oil Filter - Installation INSTALLATION 1. Lightly lubricate oil filter gasket with engine oil. 2. Thread filter onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one half turn, or 180°,do not over tighten. 3. Add oil, verify crankcase oil level and start engine. Inspect for oil leaks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications OIL PAN Oil Pan Bolts......................................................................................................................................... ........................................................12 Nm (9 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal Oil Pan: Service and Repair Engine Oil Pan - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 4X2 1. Power down the vehicle See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Loosen both left and right side engine mount through bolts. Do not remove bolts. 3. Install Engine Support Fixture 8534B (1). Do not raise engine at this time. 4. Remove fan and fan shroud. 5. Remove the structural collar See: Service and Repair/Removal and Replacement/Structural Dust Cover - Removal. 6. Drain engine oil. 7. Remove the front crossmemberSee: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal > Page 2358 8. Raise engine using Engine Support Fixture 8534B to provide clearance to remove oil pan. NOTE: Do not pry on oil pan or oil pan gasket. Gasket is integral to engine windage tray and does not come out with oil pan. NOTE: If more clearance is needed to remove oil pan, the transmission mount can be removed, and the transmission raised to gain clearance. NOTE: The double ended oil pan studs must be installed in the same location that they were removed from. 9. Remove the oil pan mounting bolts using the sequence provided. 10. Unbolt oil pump pickup tube and remove tube. NOTE: When the oil pan is removed, a new integral windage tray and gasket assembly must be installed. The old gasket cannot be reused. 11. Discard the integral windage tray and gasket and replace. 4X4 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal > Page 2359 1. Follow all steps for 4X2 removal. 2. Unbolt and lower the steering rack, without disconnecting the lines. NOTE: The front axle must be lowered to remove the oil pan on 4X4 vehicles. 3. Remove the front driveshaft at the axle. Mark for reassembly. 4. Support the front axle. 5. Remove the right and left axle to mount, bolts. 6. Lower axle. 7. Remove the oil pan mounting bolts and oil pan. 8. Unbolt oil pump pickup tube and remove tube. NOTE: When the oil pan is removed, a new integral windage tray and gasket assembly must be installed. The old gasket cannot be reused. 9. Discard the integral windage tray and gasket and replace. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal > Page 2360 Oil Pan: Service and Repair Engine Oil Pan - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Clean the oil pan gasket mating surface of the block and oil pan. NOTE: Mopar(R) Engine RTV must be applied to the 4 T-joints (1,2), (area where front cover, rear retainer, block, and oil pan gasket meet). The bead of RTV should cover the bottom of the gasket. This area is approximately 4.5 mm x 25 mm in each of the 4 T-joint locations. 2. Apply Mopar(R) Engine RTV at the 4 T- joints (1,2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal > Page 2361 NOTE: When the oil pan is removed, a new integral windage tray and gasket assembly must be installed. The old gasket cannot be reused. 3. Install a new integral windage tray and gasket. 4. Install the oil pump pickup tube with new O-ring. Tighten tube to pump fasteners to 28 Nm (250 in. lbs.). NOTE: The double ended oil pan studs must be installed in the same location that they were removed from. 5. Position the oil pan and install the mounting bolts and studs. Tighten the mounting bolts to 12 Nm (105 in.lbs.). 6. Install the structural collar See: Service and Repair/Removal and Replacement/Structural Dust Cover - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair > Engine Oil Pan - Removal > Page 2362 7. Lower the engine into mounts using Engine Support Fixture 8534B (1). 8. Install both the left and right side engine mount through bolts. Tighten the nuts to 68 Nm (50 ft. lbs.). 9. Install the front axle, if removed. 10. Install the steering rack, if removed. 11. Install the rear transmission mount, if removed. 12. Remove Engine Support Fixture 8534B (1). 13. Install the front crossmember See: Body and Frame/Frame/Cross-Member/Service and Repair/Crossmember - Installation. 14. Install the fan shroud and fan. 15. Fill engine oil. 16. Power up the vehicle . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 17. Start engine and check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2366 Oil Pressure Sender: Diagrams Connector - (ENGINE) 2 WAY SWITCH-OIL PRESSURE - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 2370 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 2371 Oil Pressure Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-OIL PRESSURE - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Locations > Page 2372 Oil Pressure Sensor: Description and Operation DESCRIPTION The oil pressure sensor uses the following three circuits: - Signal circuit to the PCM - Sensor ground circuit through the PCM - 5 volt reference circuit from the PCM The oil pressure sensor returns a voltage signal back to the PCM with reference to oil pressure. Ground for the sensor is supplied by the PCM. The oil pressure sensor is located on the right side of the engine block. The sensor screws into the engines main oil gallery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair > Oil Pressure Sensor - Removal Oil Pressure Sensor: Service and Repair Oil Pressure Sensor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the High Voltage Power Down Procedure . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Raise and support the vehicle. 3. Disconnect the oil pressure sensor electrical connector (1). 4. Remove the oil pressure sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair > Oil Pressure Sensor - Removal > Page 2375 Oil Pressure Sensor: Service and Repair Oil Pressure Sensor - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions NOTE: Apply Mopar(R) Thread Sealant with PTFE to the sensor threads before installing into the engine block. 1. Install the oil pressure sensor (1). 2. Connect the oil pressure sensor electrical connector (1). 3. Lower the vehicle. 4. Perform the High Voltage Power Up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Low Oil Pressure Indicator - Description Oil Pressure Warning Lamp/Indicator: Description and Operation Low Oil Pressure Indicator Description DESCRIPTION A low oil pressure indicator is standard equipment on all instrument clusters. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The low oil pressure indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine Oil in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The low oil pressure indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Low Oil Pressure Indicator - Description > Page 2380 Oil Pressure Warning Lamp/Indicator: Description and Operation Low Oil Pressure Indicator Operation OPERATION The low oil pressure indicator gives an indication to the vehicle operator when the engine oil pressure reading reflects a condition requiring immediate attention. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The low oil pressure indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the low oil pressure indicator for the following reasons: - Engine Oil Pressure Low Message - Each time the cluster receives an electronic engine oil pressure message from the PCM indicating the pressure is about 6.9 kPa (1 psi) or lower, the low oil pressure indicator illuminates. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the pressure is above about 6.9 kPa (1 psi), or until the ignition switch turns to the OFF position, whichever occurs first. The cluster only turns the indicator on in response to low engine oil pressure if the engine speed is greater than zero. - Self Test - Each time the cluster is put through the self test, the low oil pressure indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM then sends the proper messages to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the low oil pressure indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the engine oil pressure sensor, the PCM, the CCN, the CAN data bus or the electronic communication related to low oil pressure indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications OIL PRESSURE At Curb Idle Speed (MIN)*.................................................................................................................... ............................................................25 kPa (4 psi) At 3000 rpm....................................................... ..........................................................................................................................170 - 758 kPa (25 110 psi) CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3000 rpm Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 2385 Engine Oil Pressure: Testing and Inspection CHECKING ENGINE OIL PRESSURE 1. Remove the oil pressure sending unit and install gauge assembly C-3292A. 2. Run the engine until thermostat opens. 3. Oil Pressure: - Curb Idle-25 kPa (4 psi) minimum - 3000 rpm-170 - 758 kPa (25 - 110 psi) 4. If oil pressure is 0 at idle, shut off engine. Check for a clogged oil pick-up screen or a pressure relief valve stuck open. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Fuel Tank Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Fuel Tank Pressure Sensor > Page 2390 Oil Temperature Sensor/Switch: Locations Engine Oil Temperature Sensor (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Fuel Tank Pressure Sensor > Page 2391 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Diagrams > Engine Oil Temperature Sensor (5.7L) (Engine) 2 Way Oil Temperature Sensor/Switch: Diagrams Engine Oil Temperature Sensor (5.7L) (Engine) 2 Way Connector (5.7L) - (ENGINE) 2 WAY SENSOR-ENGINE OIL TEMPERATURE (5.7L) - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Diagrams > Engine Oil Temperature Sensor (5.7L) (Engine) 2 Way > Page 2394 Oil Temperature Sensor/Switch: Diagrams Fuel Tank Pressure Sensor (Chassis) 3 Way Connector - (CHASSIS) 3 WAY SENSOR-FUEL TANK PRESSURE - (CHASSIS) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Diagrams > Page 2395 Oil Temperature Sensor/Switch: Description and Operation DESCRIPTION The oil temperature sensor uses the following two circuits: - Signal circuit to the PCM - Ground circuit from the PCM The oil temperature sensor is a Negative Thermal Coefficient sensor. The resistance of the sensor changes as oil temperature changes. This results in different output voltages back to the PCM. The oil temperature sensor is located on the right side of the engine block. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Oil Temperature Sensor - Removal Oil Temperature Sensor/Switch: Service and Repair Oil Temperature Sensor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the High Voltage Power Down Procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Raise and support the vehicle. 3. Disconnect the oil temperature sensor electrical connector (1). 4. Remove the oil temperature sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Oil Temperature Sensor - Removal > Page 2398 Oil Temperature Sensor/Switch: Service and Repair Oil Temperature Sensor - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions NOTE: Apply Mopar(R) Thread Sealant with PTFE to the sensor threads before installing into the engine block. 1. Install the oil temperature sensor (1). 2. Connect the oil temperature sensor electrical connector (1). 3. Lower the vehicle. 4. Perform the High Voltage Power Up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications INTAKE MANIFOLD/THROTTLE BODY Intake Manifold Bolts............................................................................................................................ ........................................................12 Nm (9 ft. lbs.) Throttle Body Mounting Bolts............................................................................................................... ....................................................5.6 Nm (50 in. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2402 Intake Manifold: Description and Operation DESCRIPTION The intake manifold is made of a composite material and features long runners which maximizes low end torque. The intake manifold uses single plane sealing which consist of eight individual press in place port gaskets to prevent leaks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2403 Intake Manifold: Testing and Inspection INTAKE MANIFOLD LEAKAGE An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or more cylinders may not be functioning. WARNING: Use extreme caution when the engine is operating. Do not stand in a direct line with the fan. Do not put your hands near the pulleys, belts or the fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 1. Start the engine. 2. Spray a small stream of water at the suspected leak area. 3. If a change in RPM is observed the area of the suspected leak has been found. 4. Repair as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures Intake Manifold: Procedures Intake Manifold - Cleaning CLEANING NOTE: There is NO approved repair procedure for the intake manifold. If severe damage is found during inspection, the intake manifold must be replaced. Before installing the intake manifold thoroughly clean the mating surfaces. Use a suitable cleaning solvent, then air dry. Intake Manifold - Inspection INSPECTION 1. Inspect the intake sealing surface for cracks, nicks and distortion. 2. Inspect the intake manifold vacuum hose fittings for looseness or blockage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2406 Intake Manifold: Removal and Replacement Intake Manifold - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the fuel system pressure release procedure See: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 3. Disconnect the 12 volt battery system ground isolation connector (1) located next to the electric vacuum pump (2). 4. Remove the cowl grille (4) See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Cover - Removal Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2407 5. Using a small screwdriver (1), remove the center air cleaner trim cover (2). 6. Disconnect the high voltage inter lock (HVIL) electrical connector (1). 7. Disconnect the brake booster hose and positive crankcase ventilation (PCV) hose. 8. Remove the clean air tube retaining bolt (3). 9. Remove the clean air tube (2). 10. Disconnect the intake air temperature (IAT) sensor connector (1). 11. Remove the center air cleaner fastener (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2408 12. Slightly raise the front of the air cleaner housing up off the throttle body and then slide forward to remove the rear air cleaner housing pegs (2) from the grommets (1) on the rear of the intake manifold. NOTE: The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If the harness is not tagged, note wiring location before removal. 13. Disconnect the electrical connectors at all fuel injectors. Push the red colored slider away from the injector while pushing slider, depress tab and remove connectors from the injectors and reposition harness out of the way. NOTE: Excessive fuel spillage onto the gaskets can cause gaskets to expand and dislodge from gasket groove. 14. Disconnect the fuel supply line quick connect fitting at the fuel rail (1) and plug the fuel supply line with a shipping cap to prevent spillage See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2409 15. Remove the EGR valve tube retaining bolts (1) and remove the tube (2). 16. Using the sequence shown, remove the intake manifold retaining bolts. 17. Slide the intake manifold forward and disconnect the manifold air pressure (MAP) sensor (3) electrical connector by sliding the release lock out (1) while pressing down on the lock tab (2) located at the rear of the intake manifold. 18. Remove the intake manifold. Intake Manifold - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2410 INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Apply Mopar(R) Lock & Seal Adhesive to the intake manifold retaining bolts. 2. Install new intake manifold seals (1,3). 3. Position the intake manifold and connect the manifold air pressure (MAP) sensor (3) electrical connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2411 4. Using the sequence shown, install the intake manifold retaining bolts and tighten to 12 Nm (9 ft. lbs.). 5. Connect the fuel supply line quick connect fitting at the fuel rail (1) See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair NOTE: The factory fuel injection wiring harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If the harness was not tagged, use wiring location noted during removal. 6. Reposition the fuel injector wiring harness and connect the electrical connectors to all fuel injectors. 7. Position the EGR valve tube (2) and install the retaining bolts (1) and tighten to 13 Nm (10 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2412 8. Verify the throttle body seal is properly aligned at the bottom of the air cleaner housing. 9. Slide the rear air cleaner housing pegs (2) into the grommets (1) on the rear of the intake manifold and lower the front of the air cleaner housing onto the throttle body. NOTE: Verify the air cleaner housing is installed properly in the rear grommets by reaching around the left rear corner of the air cleaner housing and feel for the pegs protruding through the rubber grommets. If the plastic pegs cannot be felt, the air cleaner housing will need to be reinstalled. 10. Install the air cleaner housing center fastener (2) and tighten to 7 Nm (62 in. lbs.) 11. Install the air cleaner trim cover. 12. Connect the intake air temperature (IAT) sensor electrical connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Procedures > Page 2413 13. Install the clean air tube (2). 14. Install the clean air tube fastener (3) and tighten to 7 Nm (62 in. lbs.). 15. Connect the high voltage inter lock (HVIL) electrical connector. 16. Connect the brake booster hose and positive crankcase ventilation (PCV) hose. 17. Install the cowl grille (4), front push pins (5) and the rear screws (1). 18. Install the wiper arms (2) and the retaining nuts (3) See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation 19. Connect the 12 volt battery system ground isolation connector (1) and secure the connector to the electric vacuum pump bracket (2). 20. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Low Oil Pressure Indicator - Description Oil Pressure Warning Lamp/Indicator: Description and Operation Low Oil Pressure Indicator Description DESCRIPTION A low oil pressure indicator is standard equipment on all instrument clusters. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The low oil pressure indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine Oil in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The low oil pressure indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Low Oil Pressure Indicator - Description > Page 2419 Oil Pressure Warning Lamp/Indicator: Description and Operation Low Oil Pressure Indicator Operation OPERATION The low oil pressure indicator gives an indication to the vehicle operator when the engine oil pressure reading reflects a condition requiring immediate attention. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The low oil pressure indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the low oil pressure indicator for the following reasons: - Engine Oil Pressure Low Message - Each time the cluster receives an electronic engine oil pressure message from the PCM indicating the pressure is about 6.9 kPa (1 psi) or lower, the low oil pressure indicator illuminates. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the pressure is above about 6.9 kPa (1 psi), or until the ignition switch turns to the OFF position, whichever occurs first. The cluster only turns the indicator on in response to low engine oil pressure if the engine speed is greater than zero. - Self Test - Each time the cluster is put through the self test, the low oil pressure indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM then sends the proper messages to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the low oil pressure indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the engine oil pressure sensor, the PCM, the CCN, the CAN data bus or the electronic communication related to low oil pressure indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Description and Operation Crankshaft Main Bearing Seal: Description and Operation DESCRIPTION The crankshaft rear oil seal is integral to the crankshaft rear oil seal retainer, for more information refer to the following; Diagnosis and Testing See: Testing and Inspection/Symptom Related Diagnostic Procedures/Rear Seal Area Leaks - Removal See: Cylinder Block Assembly/Crankshaft Seal Retainer/Service and Repair/Crankshaft Rear Oil Seal Retainer - Removal - Installation See: Cylinder Block Assembly/Crankshaft Seal Retainer/Service and Repair/Crankshaft Rear Oil Seal Retainer - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Front Crankshaft Oil Seal - Removal Front Crankshaft Seal: Service and Repair Front Crankshaft Oil Seal - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Remove the water pump drive belt (1) See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal 3. Drain the cooling system See: Cooling System/Service and Repair 4. Remove the upper radiator hose. 5. Remove the radiator, radiator cooling fan and shroud as an assembly See: Cooling System/Radiator Cooling Fan 6. Remove the crankshaft damper bolt. 7. Remove the vibration damper using crankshaft insert 8513A (2) and three jaw puller 1023 (1) See: Cylinder Block Assembly/Harmonic Balancer Crankshaft Pulley/Service and Repair/Vibration Damper - Removal Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Front Crankshaft Oil Seal - Removal > Page 2428 8. Using seal remover 9071 (1), remove the crankshaft front seal (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Front Crankshaft Oil Seal - Removal > Page 2429 Front Crankshaft Seal: Service and Repair Front Crankshaft Oil Seal - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions CAUTION: The front crankshaft seal must be installed dry. Do not apply lubricant to the sealing lip or the outer edge. 1. Using the crankshaft front oil seal installer 9072 (2) and damper installer 8512A (1), install the crankshaft front oil seal. CAUTION: To prevent severe damage to the crankshaft or damper, thoroughly clean the damper bore and the crankshaft nose before installing damper. 2. Install the vibration damper See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Vibration Damper Installation 3. Install the radiator cooling fan and shroud assembly See: Cooling System/Radiator Cooling Fan 4. Install the upper radiator hose. 5. Install the water pump drive belt (1) See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. 6. Refill cooling system See: Cooling System/Service and Repair 7. Perform the HEV high voltage power up procedure . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Front Crankshaft Oil Seal - Removal > Page 2430 System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Description and Operation Valve Guide Seal: Description and Operation DESCRIPTION The valve guide seals are made of rubber and incorporate an integral steel valve spring seat. The integral garter spring maintains consistent lubrication control to the valve stems. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2438 Oil Pressure Sender: Diagrams Connector - (ENGINE) 2 WAY SWITCH-OIL PRESSURE - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 2442 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 2443 Oil Pressure Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-OIL PRESSURE - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Locations > Page 2444 Oil Pressure Sensor: Description and Operation DESCRIPTION The oil pressure sensor uses the following three circuits: - Signal circuit to the PCM - Sensor ground circuit through the PCM - 5 volt reference circuit from the PCM The oil pressure sensor returns a voltage signal back to the PCM with reference to oil pressure. Ground for the sensor is supplied by the PCM. The oil pressure sensor is located on the right side of the engine block. The sensor screws into the engines main oil gallery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Oil Pressure Sensor - Removal Oil Pressure Sensor: Service and Repair Oil Pressure Sensor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the High Voltage Power Down Procedure . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Raise and support the vehicle. 3. Disconnect the oil pressure sensor electrical connector (1). 4. Remove the oil pressure sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair > Oil Pressure Sensor - Removal > Page 2447 Oil Pressure Sensor: Service and Repair Oil Pressure Sensor - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions NOTE: Apply Mopar(R) Thread Sealant with PTFE to the sensor threads before installing into the engine block. 1. Install the oil pressure sensor (1). 2. Connect the oil pressure sensor electrical connector (1). 3. Lower the vehicle. 4. Perform the High Voltage Power Up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Fuel Tank Pressure Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Fuel Tank Pressure Sensor > Page 2452 Oil Temperature Sensor/Switch: Locations Engine Oil Temperature Sensor (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations > Fuel Tank Pressure Sensor > Page 2453 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Diagrams > Engine Oil Temperature Sensor (5.7L) (Engine) 2 Way Oil Temperature Sensor/Switch: Diagrams Engine Oil Temperature Sensor (5.7L) (Engine) 2 Way Connector (5.7L) - (ENGINE) 2 WAY SENSOR-ENGINE OIL TEMPERATURE (5.7L) - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Diagrams > Engine Oil Temperature Sensor (5.7L) (Engine) 2 Way > Page 2456 Oil Temperature Sensor/Switch: Diagrams Fuel Tank Pressure Sensor (Chassis) 3 Way Connector - (CHASSIS) 3 WAY SENSOR-FUEL TANK PRESSURE - (CHASSIS) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Diagrams > Page 2457 Oil Temperature Sensor/Switch: Description and Operation DESCRIPTION The oil temperature sensor uses the following two circuits: - Signal circuit to the PCM - Ground circuit from the PCM The oil temperature sensor is a Negative Thermal Coefficient sensor. The resistance of the sensor changes as oil temperature changes. This results in different output voltages back to the PCM. The oil temperature sensor is located on the right side of the engine block. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Oil Temperature Sensor - Removal Oil Temperature Sensor/Switch: Service and Repair Oil Temperature Sensor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the High Voltage Power Down Procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Raise and support the vehicle. 3. Disconnect the oil temperature sensor electrical connector (1). 4. Remove the oil temperature sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Service and Repair > Oil Temperature Sensor - Removal > Page 2460 Oil Temperature Sensor/Switch: Service and Repair Oil Temperature Sensor - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions NOTE: Apply Mopar(R) Thread Sealant with PTFE to the sensor threads before installing into the engine block. 1. Install the oil temperature sensor (1). 2. Connect the oil temperature sensor electrical connector (1). 3. Lower the vehicle. 4. Perform the High Voltage Power Up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications CAMSHAFT GEAR/SPROCKET Camshaft Sprocket Bolt........................................................................................................................ .....................................................122 Nm (90 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain & Sprockets - Removal Timing Chain: Service and Repair Timing Chain & Sprockets - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System High Voltage Power Down 2. Disconnect the 12 volt battery system ground isolation connector (1). 3. Drain the cooling system. 4. Remove the timing chain cover See: Timing Cover/Service and Repair/Engine Timing Cover(s) - Removal 5. Remove the oil pump retaining bolts (2) and remove the oil pump (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain & Sprockets - Removal > Page 2469 6. Install the vibration damper bolt finger tight. Using a suitable socket and breaker bar, rotate the crankshaft to align timing chain sprockets and keyways as shown. 7. Retract the tensioner shoe (1) with pliers (2) until the hole in shoe lines up with the hole in bracket. 8. Install the Tensioner Pin 8514 (1) into the holes. 9. Remove the timing chain tensioner retaining bolts (3) and remove the timing chain tensioner (2). 10. Inspect the timing chain tensioner and replace as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain & Sprockets - Removal > Page 2470 11. Remove the timing chain guide (1) retaining bolts (2) and remove the timing chain guide. 12. Inspect the timing chain guide and replace as necessary. 13. Remove the camshaft sprocket retaining bolt (1) and remove the timing chain with the camshaft and crankshaft sprockets. 14. Inspect the timing chain, camshaft and crankshaft sprockets and replace as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain & Sprockets - Removal > Page 2471 Timing Chain: Service and Repair Timing Chain & Sprockets - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Slide the crankshaft sprocket (1) on the crankshaft. 2. Position the timing chain onto the crankshaft sprocket and align the timing marks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain & Sprockets - Removal > Page 2472 3. Position the timing chain onto the camshaft sprocket and align the camshaft timing marks and install the camshaft sprocket on the camshaft while sliding the crankshaft sprocket into position. 4. Install the camshaft retaining bolt finger tight. 5. Install the timing chain guide (1) and tighten bolts (2) to 12 Nm (9 ft. lbs.). 6. Install the timing chain tensioner (2) and tighten bolts (3) 12 Nm (9 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain & Sprockets - Removal > Page 2473 7. Verify the timing marks (1,2) are aligned correctly. 8. Remove the timing chain Tensioner Pin 8514 (1). 9. Tighten the camshaft sprocket bolt (1) to 122 Nm (90 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Timing Chain & Sprockets - Removal > Page 2474 10. Install the oil pump (1) See: Engine Lubrication/Oil Pump/Service and Repair/Removal and Replacement 11. Install the timing chain cover See: Timing Cover/Service and Repair/Engine Timing Cover(s) - Installation 12. Fill the engine with oil. 13. Fill the cooling system See: Cooling System/Service and Repair 14. Perform the high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System High Voltage Power Up 15. Connect the 12 volt battery system ground isolation connector (1). 16. Start the engine and check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications TIMING CHAIN TENSIONER Timing Chain Tensioner Bolts.............................................................................................................. .........................................................12 Nm (9 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Description and Operation > Timing Chain Tensioner - Description Timing Chain Tensioner: Description and Operation Timing Chain Tensioner - Description DESCRIPTION The timing chain tensioner is a spring loaded design. It consists of two chain guide shoes. One shoe is fixed in place and the other is spring loaded to keep tension on the chain. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Description and Operation > Timing Chain Tensioner - Description > Page 2480 Timing Chain Tensioner: Description and Operation Timing Chain Tensioner - Operation OPERATION The timing chain tension is maintained by routing the timing chain through the tensioner assembly. A nylon shoe presses on the timing chain maintaining the correct chain tension. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications TIMING COVER Timing Chain Case Cover Bolts........................................................................................................... .......................................................28 Nm (21 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal Timing Cover: Service and Repair Engine Timing Cover(s) - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the high voltage power down procedure . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System High Voltage Power Down 2. Remove the engine cover. 3. Remove air cleaner assembly See: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body Removal. 4. Drain cooling system. 5. Remove water pump drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 6. Remove coolant bottle and washer bottle. 7. Remove upper radiator hose. 8. Disconnect both heater hoses (1,3) at timing cover. 9. Disconnect lower radiator hose at engine. 10. Remove crankshaft damper See: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Vibration Damper Removal. 11. Remove the dipstick support bolt. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 2486 12. Drain the engine oil. 13. Remove the oil pan and pick up tubeSee: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Removal. NOTE: It is not necessary to remove water pump for timing cover removal. 14. Remove timing cover bolts and remove cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 2487 Timing Cover: Service and Repair Engine Timing Cover(s) - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Clean timing chain cover and block sealing surfaces. NOTE: Always install a new gasket on timing cover. 2. Install cover and new gasket. Tighten fasteners to 28 Nm (250 in. lbs.) in the sequence shown. 3. The large lifting stud (1) is tightened to 55 Nm (40 ft. lbs.). 4. Install the oil pan and pick up tubeSee: Engine Lubrication/Oil Pan/Service and Repair/Engine Oil Pan - Installation. 5. Install the dipstick support bolt. 6. Install the thermostat housing. 7. Install crankshaft damperSee: Cylinder Block Assembly/Harmonic Balancer - Crankshaft Pulley/Service and Repair/Vibration Damper Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Engine Timing Cover(s) - Removal > Page 2488 8. Install radiator lower hose (2). 9. Install both heater hoses (1,3). 10. Install the cooling moduleSee: Cooling System/Radiator/Service and Repair/Removal and Replacement/Engine Cooling Radiator - Installation. 11. Install the water pump drive belt See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. 12. Install the upper radiator hose. 13. Install the air cleaner assemblySee: Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body Installation. 14. Fill cooling system. 15. Fill engine oil. 16. Perform high voltage power up procedure . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Valve Timing Assembly Description Variable Valve Timing Actuator: Description and Operation Variable Valve Timing Assembly Description DESCRIPTION The 5.7L Eagle engine is equipped with Variable Cam Timing (VCT). This system advances and/or retards the camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The VCT assembly is sometimes referred to as a camshaft phaser. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. The VCT assembly consists of the camshaft sprocket and a timing phaser. The VCT phaser assembly bolts to the camshaft and is serviced as an assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Valve Timing Assembly Description > Page 2494 Variable Valve Timing Actuator: Description and Operation Variable Valve Timing Assembly Operation OPERATION The Variable Cam Timing (VCT) assembly is actuated with engine oil pressure. The oil flow to the VCT assemblies are controlled by an Oil Control Valve (OCV). The OCV consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VCT assemblies. The VCT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VCT assembly rotates the rotor with respect to the stator, thus rotating the exhaust camshaft with respect to the timing chain and intake camshaft. An infinitely variable cam timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Service and Repair > Variable Valve Timing Assembly Removal Variable Valve Timing Actuator: Service and Repair Variable Valve Timing Assembly - Removal REMOVAL CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. 1. Remove the timing chain and sprockets See: Timing Chain/Service and Repair/Timing Chain & Sprockets - Removal 2. Remove the camshaft phaser bolt (1). 3. Remove camshaft phaser (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Actuator > Component Information > Service and Repair > Variable Valve Timing Assembly Removal > Page 2497 Variable Valve Timing Actuator: Service and Repair Variable Valve Timing Assembly - Installation INSTALLATION 1. Align the slot (2) in the phaser (1) with the dowel on the camshaft. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. 2. Position the phaser (2) in place and install phaser retaining bolt (1) and tighten to 122 Nm (90 ft. lbs.). 3. Install the timing chain and sprockets See: Timing Chain/Service and Repair/Timing Chain & Sprockets - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Diagrams Variable Valve Timing Solenoid: Diagrams Connector (5.7L) - 2 WAY SOLENOID-VARIABLE CAMSHAFT TIMING (5.7L) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation > Oil Intake Control Valve Operation Variable Valve Timing Solenoid: Description and Operation Oil Intake Control Valve - Operation OPERATION The Variable Valve Timing (VVT) assembly is actuated with engine oil pressure. The oil flow to the VVT assemblies are controlled by an Oil Control Valve (OCV). The OCV consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VVT assemblies. The VVT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VVT assembly rotates the rotor with respect to the stator, thus rotating the exhaust camshaft with respect to the timing chain and intake camshaft. An infinitely variable valve timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Description and Operation > Oil Intake Control Valve Operation > Page 2503 Variable Valve Timing Solenoid: Description and Operation Oil Intake Control Valve - Description DESCRIPTION The 5.7L engine is equipped with Variable Valve Timing (VVT). This system uses an oil control valve to direct oil pressure into the camshaft phaser assembly. The camshaft phaser assembly advances and/or retards camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The oil control valve is located under the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Oil Intake Control Valve - Installation Variable Valve Timing Solenoid: Service and Repair Oil Intake Control Valve - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Install the oil control valve (OCV) (1). 2. Securely tighten the OCV fastener. 3. Connect the OCV electrical connector (2). 4. Install the intake manifold See: Intake Manifold/Service and Repair/Removal and Replacement/Intake Manifold - Installation 5. Connect the 12 volt battery system ground isolation connector (1) located next to the electric vacuum pump (2). 6. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Oil Intake Control Valve - Installation > Page 2506 Variable Valve Timing Solenoid: Service and Repair Oil Intake Control Valve - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the fuel system pressure release procedure See: Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Disconnect the 12 volt battery system ground isolation connector (1) located next to the electric vacuum pump (2). 3. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 4. Remove the intake manifold See: Intake Manifold/Service and Repair/Removal and Replacement/Intake Manifold - Removal 5. Disconnect the oil control valve (OCV) electrical connector (2). 6. Remove the OCV fastener (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing > Variable Valve Timing Solenoid > Component Information > Service and Repair > Oil Intake Control Valve - Installation > Page 2507 NOTE: To remove the oil control valve, the engine must be at room temperature. 7. Rotate the OCV to break the seal and pull the OCV out of the cylinder block. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE The correct fuel pressure for this vehicle is 58 psi +/- 2 psi Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2512 Fuel Pressure: Testing and Inspection FUEL PRESSURE LEAK DOWN For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: Follow these safety precautions to reduce the risk of fire and serious possible serious or fatal injury when performing this test procedure. Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. Use extreme caution when connecting and disconnecting fuel lines. - Considerable fuel leakage may occur when servicing the fuel system. Wear protective eye wear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair / replace as necessary. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A 1. Turn the ignition off. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2513 WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from Gas and Diesel Fuel Pressure/Decay Tester 8978A. Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978A-1 (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect the Reservoir Assembly 534960 (4) to the Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 2514 - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 2. Turn the ignition on, wait five seconds, turn the ignition off and then wait 1 minute before proceeding. 3. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 Kpa +/- 34 Kpa (59 psi +/- 5 psi). SRT-4 fuel pressure specification is 552 Kpa +/- 34 Kpa (80 psi +/- 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the Checking The Fuel Delivery System diagnostic procedure as directed. 5. CHECK FUEL DELIVERY SYSTEM FOR LEAK DOWN WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Close the Fuel System Isolation Valve (1) and then wait five minutes before proceeding. 2. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge (1) - Replace the fuel pump module. - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Yes - On Fuel Outlet Gauge (2) - Replace the leaking fuel injector(s). - Perform the PCM VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. No - If directed here by another test, return to that test. Otherwise, test complete. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal Air Filter Element: Service and Repair Air Cleaner - Removal REMOVAL - AIR FILTER ELEMENT - HEV 1. Remove the air cleaner trim covers (2) with a small screwdriver (1). 2. Remove the air clean cover fasteners (1). 3. Unclip the air cleaner cover latches (2). 4. Remove the air cleaner cover (3). 5. Remove the air filter element (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 2520 Air Filter Element: Service and Repair Air Cleaner - Installation INSTALLATION - AIR FILTER ELEMENT - HEV 1. Install a new filter element (1). 2. Install the air cleaner cover (3). 3. Install the air cleaner cover fasteners (1). 4. Secure the air cleaner cover latches (2). 5. Install the air cleaner trim covers (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions Use the following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove the fuel fill cap. 2. Remove the fuel pump relay or the fuel pump speed relay from the Power Distribution Center (PDC) (1), refer to the label on the underside of the PDC cover for relay locations or See: Maintenance/Fuses and Circuit Breakers/Fuse/Locations/Fuse Panel 3. Start and run the engine until it stalls. 4. Attempt restarting the engine until it will no longer run. 5. Turn the ignition key to the OFF position. 6. Disconnect the 12 volt battery system ground isolation connector (1). 7. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down NOTE: Excessive fuel spillage onto the gaskets can cause gaskets to expand and dislodge from gasket groove. 8. Place a rag or towel around the fuel line quick-connect fitting at the fuel rail to prevent residual fuel spray or spillage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 2525 9. Disconnect the fuel supply line quick connect fitting at the fuel rail (1) and plug the fuel supply line with a shipping cap See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair 10. Return the fuel pump relay or the fuel pump speed relay to the PDC. NOTE: One or more Diagnostic Trouble Code(s) (DTC) may have been stored in the PCM memory due to the fuel pump relay removal. A diagnostic scan tool must be used to erase a DTC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications ENGINE FIRING ORDER - 5.7L The firing order for the 5.7L V-8 is 1-8-4-3-6-5-7-2. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications IGNITION TIMING Ignition timing is not adjustable on any of the available engines. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications Spark Plug: Specifications Spark Plug Specifications SPARK PLUGS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications > Page 2536 Spark Plug: Specifications Torque SPARK PLUG TORQUES Spark Plugs - 3.7L................................................................................................................................ .......................................................27 Nm (20 ft. lbs.) Spark Plugs - All 4.7L (Upper or Lower row) (New plugs/gaskets).......................................................................................................27±3 Nm (20 ft. lbs.) Spark Plugs - All 4.7L (Upper or Lower row) (Used plugs/gaskets).......................................................................................................22±3 Nm (16 ft. lbs.) **Spark Plugs - 5.7L............................................................................................................................. ........................................ 18(±3) Nm (13(±2) ft. lbs.) ** Torque critical tapered design. Do not exceed 15 ft.lbs. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal Spark Plug: Service and Repair Spark Plug - Removal 5.7L 1. Remove all the necessary air filter tubing and air intake components at the top of the engine and at the throttle body See: Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal 2. Prior to removing the ignition coil, spray compressed air around the base of the ignition coil at the cylinder head. 3. Remove the ignition coil (1) See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil - Removal 4. Prior to removing the spark plug, spray compressed air into the cylinder head opening. 5. Remove the spark plug from the cylinder head using a quality thin wall socket with a rubber or foam insert. 6. Inspect the spark plug condition. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 2539 Spark Plug: Service and Repair Spark Plug - Installation 5.7L CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. CAUTION: Do not attempt to clean any of the spark plugs. Replace only. 1. Check and adjust the spark plug gap with a gap gauging tool (1) See: Specifications/Spark Plug Specifications. CAUTION: Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. 2. Start the spark plug into the cylinder head by hand to avoid cross threading. NOTE: Always tighten spark plugs to the specified torque. Certain engines use torque sensitive spark plugs. Over tightening can cause distortion resulting in a change in the spark plug gap, or a cracked porcelain insulator. NOTE: Spark plugs have a torque critical tapered design. Do not exceed 20 Nm (15 ft. lbs.). 3. Tighten the spark plugs to 18 Nm (13 ft. lbs.). 4. To aid in coil installation, apply silicone based grease such as Mopar(R) Dielectric Grease into spark plug end of ignition coil rubber boots. Also apply this grease to the tops of spark plugs. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 2540 5. Install the ignition coil(s) (1) See: Powertrain Management/Ignition System/Ignition Coil/Service and Repair/Ignition Coil - Installation 6. Install all necessary air filter tubing and air intake components to top of engine and to throttle body See: Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications PRESSURE/VARIATION Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2544 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE LEAKAGE NOTE: The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. NOTE: Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs and record the cylinder number of each spark plug for future reference. 3. Inspect the spark plug electrodes for abnormal firing indicators such as fouled, hot, oily, etc. 4. Disable the fuel system See: Fuel Filter/Fuel Pressure Release/Service and Repair and perform the fuel system pressure release procedure. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 7. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 8. If one or more cylinders have abnormally low compression pressures, repeat the compression test. NOTE: If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. 9. If one or more cylinders continue to have abnormally low compression pressures, perform the cylinder combustion pressure leakage test See: Testing and Inspection/Component Tests and General Diagnostics/Cylinder Combustion Pressure Leakage Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications WATER PUMP Water Pump-to-Timing Chain Case Cover Bolts.........................................................................................................................................28 Nm (21 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2548 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2549 Water Pump: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 4 WAY PUMP-TPIM COOLING (HEV) - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Water Pump - Description Water Pump: Description and Operation Water Pump - Description 5.7L HEV ENGINE A centrifugal water pump (1) circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven by a single drive belt that is driven by the crankshaft pulley. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The 5.7L HEV water pump also incorporates an internal electrically controlled clutch to improver warm up emissions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Water Pump - Description > Page 2552 Water Pump: Description and Operation Water Pump - Operation WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Water Pump - Description > Page 2553 Water Pump: Description and Operation TPIM Coolant Pump - Description TPIM COOLANT PUMP The TPIM coolant pump (5) is a 50 watt electric pump is used to circulate coolant through the TPIM (7) to remove heat built up by the high voltage converters in the TPIM assembly. Coolant is circulated through the combination transmission/TPIM (3) to dissipate this heat into the atmosphere. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Water Pump - Description > Page 2554 Water Pump: Description and Operation TPIM Coolant Pump - Operation TPIM COOLANT PUMP Coolant is drawn from the coolant recovery container (2) by the TPIM coolant pump (1). It flows through the combination transmission fluid/TPIM cooler through the TPIM back into the coolant recovery container. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description and Operation > Page 2555 Water Pump: Testing and Inspection ON-BOARD DIAGNOSIS - (OBD) The HYBRID CONTROL PROCESSOR (HCP) has been programmed to monitor certain cooling system component.: If the problem is sensed in a monitored circuit often enough to indicated an actual problem, a DTC is stored. The DTC will be stored in the HCP memory for eventual display to the technician See: Powertrain Management/Computers and Control Systems/Testing and Inspection ACCESSING DIAGNOSTIC TROUBLE CODES To read DTCs and to obtain cooling system data, See: Powertrain Management/Computers and Control Systems/Testing and Inspection ERASING TROUBLE CODES After the problem has been repaired, use the scan tool to erase a DTC, Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures Water Pump: Procedures Water Pump - Coolant Air Evacuation COOLANT AIR EVACUATION Evacuating or purging air from the cooling system involves the use of a pressurized air operated vacuum generator. The vacuum created allows for a quick and complete coolant refilling while removing any air locks present in the system components. NOTE: To avoid damage to the cooling system, ensure that no component would be susceptible to damage when a vacuum is drawn on the system. WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASED COOLANT PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE; PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED; PERSONAL INJURY CAN RESULT. WARNING: WEAR APPROPRIATE EYE AND HAND PROTECTION WHEN PERFORMING THIS PROCEDURE. NOTE: The service area where this procedure is performed should have a minimum shop air requirement of 80 PSI (5.5 bar) and should be equipped with an air dryer system. NOTE: For best results, the radiator should be empty. The vehicle's heater control should be set to the heat position (ignition may need to be turned to the on position but do not start the motor). 1. Refer to the Chrysler Penta star Service Equipment (Chrysler PSE) Coolant Refiller #85-15-0650 or equivalent tool's operating manual for specific assembly steps. 2. Choose an appropriate adapter cone that will fit the vehicle's radiator filler neck or reservoir tank. 3. Attach the adapter cone (2) to the vacuum gauge (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2558 4. Make sure the vacuum generator/venturi ball valve (3) is closed and attach an airline hose (2) (minimum shop air requirement of 80 PSI/5.5 bar) to the vacuum generator/venturi (1). 5. Position the adaptor cone/vacuum gauge assembly into the radiator filler neck or reservoir tank. Ensure that the adapter cone is sealed properly. 6. Connect the vacuum generator/venturi (2) to the positioned adaptor cone/vacuum gauge assembly (1). 7. Open the vacuum generator/venturi ball valve. NOTE: Do not bump or move the assembly as it may result in loss of vacuum. Some radiator overflow hoses may need to be clamped off to obtain vacuum. 8. Let the system run until the vacuum gauge shows a good vacuum through the cooling system. Refer to the tool's operating manual for appropriate pressure readings. NOTE: If a strong vacuum is being created in the system, it is normal to see the radiator hoses to collapse. 9. Close the vacuum generator/venturi ball valve. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2559 10. Disconnect the vacuum generator/venturi and airline from the adaptor cone/vacuum gauge assembly. 11. Wait approximately 20 seconds, if the pressure readings do not move, the system has no leaks. If the pressure readings move, a leak could be present in the system and the cooling system should be checked for leaks and the procedure should be repeated. 12. Place the tool's suction hose into the coolant's container. NOTE: Ensure there is a sufficient amount of coolant, mixed to the required strength/protection level available for use. For best results and to assist the refilling procedure, place the coolant container at the same height as the radiator filler neck. Always draw more coolant than required. If the coolant level is too low, it will pull air into the cooling system which could result in air locks in the system. 13. Connect the tool's suction hose (1) to the adaptor cone/vacuum gauge assembly (2). 14. Open the suction hose's ball valve to begin refilling the cooling system. 15. When the vacuum gauge reads zero, the system is filled. NOTE: On some remote pressurized tanks, it is recommended to stop filling when the proper level is reached. 16. Close the suction hose's ball valve and remove the suction hose from the adaptor cone/vacuum gauge assembly. 17. Remove the adaptor cone/vacuum gauge assembly from the radiator filler neck or reservoir tank. 18. With heater control unit in the HEAT position, operate engine with container cap in place. 19. After engine has reached normal operating temperature, shut engine off and allow it to cool. When engine is cooling down, coolant will be drawn into the radiator from the pressure container. 20. Add coolant to the recovery bottle/container as necessary. Only add coolant to the container when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion. Add necessary coolant to raise container level to the COLD MINIMUM mark after each cool down period. 21. Once the appropriate coolant level is achieved, attach the radiator cap or reservoir tank cap. Water Pump - Cleaning WATER PUMP Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2560 To ensure proper gasket sealing, surface preparation must be performed, especially with the use of aluminum engine components. Never use the following to clean gasket surfaces: - Metal scraper. - Abrasive pad or paper to clean cylinder block and head. - High speed power tool with an abrasive pad or a wire brush). - High speed power tool with 3M Roloc(TM) Bristle Disc (white or yellow). Only use the following for cleaning gasket surfaces: - Solvent or a commercially available gasket remover - Plastic or wood scraper. Water Pump - Inspection WATER PUMP Inspect the water pump assembly for cracks in the housing, water leaks from the shaft seal, worn bearing or the impeller rubbing either the pump body or the timing chain case/cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2561 Water Pump: Removal and Replacement Water Pump - Removal 5.7L ENGINE - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform HEV specific high voltage power down and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the negative battery cable. CAUTION: Disconnecting the 12 V battery from the vehicle within two minutes of the last ignition key transition from Off to Run may cause a Battery Pack Control Module (BPCM) State Of Charge (SOC) mismatch. 3. Raise and support the vehicle. 4. Drain the coolant from the radiator.See: Cooling System/Service and Repair 5. Remove the lower radiator hose from the water pump (2). 6. Disconnect the heater hoses from the water pump fittings (3). 7. Remove the accessory drive belt.See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal 8. Remove the lower water pump (2) bolts (5 total). 9. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2562 10. Remove pushpins (1) and the upper condenser/radiator seal (2). 11. Remove the upper radiator support bracket bolts (2) and the upper radiator support bracket (3). 12. Remove the upper radiator hose. 13. Remove the EGR tube at the throttle body. 14. Remove the throttle body assembly.See: Powertrain Management/Fuel Delivery and Air Induction/Throttle Body/Service and Repair/Throttle Body - Removal 15. Disconnect the A/C compressor high voltage cables at the TIPM module. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Hybrid Battery Bus / Cable/Service and Repair/High Voltage Battery Cable - Removal 16. Disconnect the electrical connector from the ECT sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2563 17. Remove the upper radiator hose from the thermostat housing (4). 18. Remove the thermostat housing (4) and thermostat from the water pump (2).See: Cooling System/Thermostat/Service and Repair/Engine Coolant Thermostat - Removal 19. Remove the water pump upper mounting bolts (7 total, 6 bolts and 1 stud). 20. Remove the water pump assembly (2). Water Pump - Installation 5.7L HEV ENGINE WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Clean gasket services. 2. Install the water pump (2) and the upper mounting bolts and stud (7 total, 6 bolts and 1 stud). Tighten the mounting bolts and stud to 28 Nm (21ft. lbs.). 3. Install the heater hoses to the water pump fittings (3). 4. Inspect the thermostat/seal assembly for damage, replace if necessary. 5. Install the thermostat and thermostat housing (4) to the water pump (2). Tighten the mounting bolts to 28 Nm (21ft. lbs.). 6. Install the upper radiator hose to the thermostat housing (4). 7. Connect the electrical connector to the ECT sensor (1). 8. Connect the A/C compressor high voltage cables. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Hybrid Battery Bus / Cable/Service and Repair/High Voltage Battery Cable - Installation 9. Install the throttle body assembly.See: Powertrain Management/Fuel Delivery and Air Induction/Throttle Body/Service and Repair/Throttle Body Installation 10. Install the EGR tube at the throttle body. 11. Connect the upper radiator hose. 12. Install the upper radiator support bracket (3). Tighten the bolts (2) to 10 N-m (89 in. lbs). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2564 13. Install the upper condenser/radiator seal (2) and pushpins (1). 14. Raise and support the vehicle. 15. Install the lower water pump (2) mounting bolts (5 total). Tighten the mounting bolts to 28 Nm (21ft. lbs.). 16. Install the accessory drive belt.See: Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation 17. Install the heater hoses (3) to the water pump (2). 18. Install the lower radiator hose to the water pump (2). 19. Evacuate air and refill cooling system.See: Procedures/Water Pump - Coolant Air Evacuation 20. Connect negative battery cable. 21. Perform HEV specific high voltage power up and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 22. Check cooling system for leaks.See: Cooling System/Testing and Inspection TPIM Coolant Pump - Removal TPIM COOLANT PUMP Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2565 WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform HEV specific high voltage power down and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the negative battery cable. CAUTION: Disconnecting the 12 V battery from the vehicle within two minutes of the last ignition key transition from Off to Run may cause a Battery Pack Control Module (BPCM) State Of Charge (SOC) mismatch. 3. Raise and support the vehicle. 4. Drain the TPIM cooling system See: Cooling System/Service and Repair/TPIM Cooling System Draining 5. Disconnect the coolant pump electrical connector (1). 6. Remove the coolant line (3). 7. Remove the coolant line (5). 8. Remove the coolant pump mounting bolts (2). 9. Remove the coolant pump and bracket (1) from the vehicle. TPIM Coolant Pump - Installation TPIM COOLANT PUMP Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Procedures > Page 2566 WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Position the coolant pump and bracket (1) on lower radiator. 2. Install the mounting bolts (2). Tighten bolts (2) to 8.6 Nm (75 in. lbs.) 3. Install the coolant line (5). 4. Install the coolant line (3). 5. Connect the coolant pump electrical connector (1). 6. Lower vehicle. 7. Connect negative battery cable. 8. Perform HEV specific high voltage power up and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 9. Fill the TPIM cooling system and check for leaks. See: Cooling System/Service and Repair/TPIM Cooling System Filling Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Auxiliary Water Pump > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Auxiliary Water Pump > Component Information > Locations > Page 2571 Auxiliary Water Pump: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 4 WAY PUMP-ELECTRIC COOLANT-HVAC (HEV) - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Auxiliary Water Pump > Component Information > Description and Operation > Auxiliary HVAC Heater Pump - Description Auxiliary Water Pump: Description and Operation Auxiliary HVAC Heater Pump - Description DESCRIPTION An auxiliary HVAC heater pump (1) is used to provide coolant flow through the front and rear heater cores on the Hybrid Electric Vehicle (HEV) models when operating the vehicle during both gasoline and electric motor operating modes. The auxiliary HVAC heater pump is mounted to the right side frame rail (4) in the engine compartment by a bracket (5) and contains an electric motor that drives a vane-type pump using a magnetic clutch. The pump housing has and electrical connector (6) for the motor and two connections for the heater hoses (2). The heater hoses are secured to the front of the pump housing by spring-type hose clamps (3). The auxiliary HVAC heater pump is of the identical design as the electric coolant pump for the Traction Power Inverter Module (TPIM), but is NOT interchangeable with the TPIM coolant pump due to different pump software. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Auxiliary Water Pump > Component Information > Description and Operation > Auxiliary HVAC Heater Pump - Description > Page 2574 Auxiliary Water Pump: Description and Operation Auxiliary HVAC Heater Pump - Operation OPERATION The auxiliary HVAC heater pump for the Hybrid Electric Vehicle (HEV) provides engine coolant flow through the front and rear heater cores during gasoline and electric motor operating modes. The auxiliary HVAC heater pump is controlled by the A/C-heater control and has a variable flow rate of approximately 8 - 19 liters (2 - 5 gallons) per minute. When the gasoline engine is operating below 1000 rpm, the auxiliary HVAC heater pump boosts engine coolant flow through the heater cores at the rate of 8 liters (2 gallons) per minute. When in electric operating mode, the A/C-heater control determines coolant flow rate based on infrared sensor data and customer temperature settings. The auxiliary HVAC heater pump is connected to the Powertrain control Module (PCM) via a Local Interconnect Network (LIN) bus. The A/C-heater control sends a flow rate command message to the Front Control Module (FCM) over the Controller Area Network (CAN) B bus. The FCM then converts and broadcasts the message over the CAN C bus to the PCM. The PCM converts the gallons per minute command from the A/C-heater control to a pump target RPM. If the A/C-heater control sends a non-zero flow rate command to the PCM and the PCM responds with a zero flow rate actual message, a Diagnostic Trouble Code (DTC) will set. The auxiliary HVAC heater pump can be actuated and diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. NOTE: The auxiliary HVAC heater pump is of the identical design as the electric coolant pump for the Traction Power Inverter Module (TPIM), but is NOT interchangeable with the TPIM coolant pump due to different pump software. The auxiliary HVAC heater pump cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Auxiliary Water Pump > Component Information > Service and Repair > Auxiliary HVAC Heater Pump - Removal Auxiliary Water Pump: Service and Repair Auxiliary HVAC Heater Pump - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Disconnect the high voltage battery system using the service disconnect at the battery pack See: Starting and Charging/Battery/Testing and Inspection. 2. Disconnect the 12 volt battery system. 3. Drain the engine cooling system See: Service and Repair. 4. Raise and support the vehicle. 5. Remove the right front wheelhouse splash shield (1) to gain access to the auxiliary HVAC heater pump (2) located on the right frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation. 6. If equipped, remove the splash shield from the auxiliary HVAC heater pump. 7. Disconnect the electrical connector (3). NOTE: If the heater hoses are cut during removal from the auxiliary HVAC heater pump, they must be replaced. 8. Loosen the hose clamps (3) and disconnect the heater hoses (2) from the auxiliary HVAC heater pump (1). 9. Remove the two bolts (5) that secure the auxiliary HVAC heater pump to the right frame rail (4) and remove the pump from the vehicle. 10. If required, remove the retaining bracket (6) from the auxiliary HVAC heater pump. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Auxiliary Water Pump > Component Information > Service and Repair > Auxiliary HVAC Heater Pump - Removal > Page 2577 Auxiliary Water Pump: Service and Repair Auxiliary HVAC Heater Pump - Installation INSTALLATION 1. If required, install the retaining bracket (6) onto the auxiliary HVAC heater pump (1). Make sure the bracket is properly orientated the pump. Tighten the bolt securely. 2. Position the auxiliary HVAC heater pump to the right frame rail (4) and install the two retaining bolts (5). Tighten the bolts to 8.5 Nm (75 in. lbs.). 3. Connect the heater hoses (2) to the auxiliary HVAC heater pump. Make sure the hose clamps (3) are securely engaged. 4. Connect the electrical connector (3) to the auxiliary HVAC heater pump (2). 5. If equipped, install the auxiliary HVAC heater pump splash shield. 6. Install the right front wheelhouse splash shield (1) See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation. 7. Lower the vehicle. 8. Reconnect the 12 volt battery system. 9. Reconnect the high voltage battery system See: Starting and Charging/Battery/Service and Repair/Procedures. 10. Refill the engine cooling system See: Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Coolant: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 2582 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Cooling System Cooling System Capacity With Rear Heat ................................................................................................................................................... 16.6 qts. (15.8L) Note: Includes 2.1 qts (2L) for coolant bottle. TPIM Cooling System TPIM Coolant System .......................................................................................................................... ............................................................ 2.3 qts (2.2L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2585 Coolant: Fluid Type Specifications Engine Coolant Mopar Antifreeze/Coolant 5 Year/100,000 Mile Formula HOAT (Hybrid Organic Additive Technology). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Description - HOAT Coolant Coolant: Description and Operation Description - HOAT Coolant HOAT COOLANT WARNING: Antifreeze is an ethylene-glycol base coolant and is harmful if swallowed or inhaled. If swallowed, drink two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after coming in contact with ethylene-glycol. Keep out of reach of children. Dispose of glycol based coolant properly, contact your dealer or government agency for location of collection center in your area. Do not open a cooling system when the engine is at operating temperature or hot under pressure, personal injury can result. Avoid radiator cooling fan when engine compartment related service is performed, personal injury can result. CAUTION: Use of Propylene-Glycol based coolants is not recommended, as they provide less freeze protection and less corrosion protection. The cooling system is designed around the coolant. The coolant must accept heat from engine metal, in the cylinder head area near the exhaust valves and engine block. Then coolant carries the heat to the radiator where the tube/fin radiator can transfer the heat to the air. The use of aluminum cylinder blocks, cylinder heads, and water pumps require special corrosion protection. Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769), or the equivalent ethylene-glycol base coolant with organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended. This coolant offers the best engine cooling without corrosion when mixed with 50% ethylene-glycol and 50% distilled water to obtain a freeze point of -37°C (-35°F). If it loses color or becomes contaminated, drain, flush, and replace with fresh properly mixed coolant solution. CAUTION: Mopar(R) Antifreeze/Coolant, 5 Year/100,000 Mile Formula (MS-9769) may not be mixed with any other type of antifreeze. Mixing of coolants other than specified (non-HOAT or other HOAT) may result in engine damage that may not be covered under the new vehicle warranty, and decreased corrosion protection. COOLANT PERFORMANCE The required ethylene-glycol and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water- Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100 percent Ethylene-Glycol - The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149°C (300°F). This temperature is hot enough to melt plastic. The increased temperature can result in severe engine damage. In addition, 100 percent ethylene-glycol freezes at -22°C (-8°F). 50/50 Ethylene-Glycol and Water - Is the recommended mixture, it provides protection against freezing to -37°C (-34°F). The antifreeze concentration must always be a minimum of 44 percent, year-round in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7°C (-90°F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water. CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Description - HOAT Coolant > Page 2588 Coolant: Description and Operation Operation COOLANT Coolant flows through the engine block and cylinder head, absorbing heat from the engine, then flows to the radiator where the cooling fins in the radiator transfer the heat from the coolant to the atmosphere. During cold weather the ethylene-glycol or propylene-glycol coolant prevents water present in the cooling system from freezing within temperatures indicated by the mixture ratio of coolant to water. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Description and Operation > Page 2589 Coolant: Testing and Inspection COOLANT CONCENTRATION TESTING Check coolant concentration when any additional coolant is added to the system, or after a coolant drain, flush and refill. Use of a hydrometer or Refractometer Tool 8286, refractometer can be used to test coolant concentration. A hydrometer tests the amount of glycol in a mixture by measuring the specific gravity of the mixture. The higher the concentration of ethylene glycol, the larger the number of balls that will float, and the higher the freeze protection (up to a maximum of 60% by volume glycol). A Refractometer Tool 8286 tests the amount of glycol in a coolant mixture by measuring the amount a beam of light bends as it passes through the fluid. Some coolant manufacturers use other types of glycols into their coolant formulations. Propylene glycol is the most common new coolant. However, propylene glycol based coolants do not provide the same freezing protection and corrosion protection and are not recommended. CAUTION: Do not mix types of coolant - corrosion protection will be severely reduced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Water Pump Inlet Tube - Removal Coolant Line/Hose: Service and Repair Water Pump Inlet Tube - Removal WATER INLET TUBE 1. Disconnect the battery negative cable. 2. Partially drain the cooling system See: Service and Repair. 3. Remove the upper radiator hose at the radiator. 4. Unplug the wiring harness from the A/C compressor. 5. Remove the air cleaner assembly See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. 6. Remove the accessory drive belt See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 7. Remove the bracket-to-intake manifold bolts. The drive belt idler pulley must be removed to gain access to one of the A/C compressor/generator bracket mounting bolts (3). 8. Remove the idler pulley bolt and the remove idler pulley. 9. Remove the oil dipstick tube mounting bolt (3) at the side of the A/C-generator mounting bracket. 10. Disconnect the throttle body cables. 11. Remove the heater hose from the heater hose return tube. 12. Remove the heater hose return tube mounting bolt and remove the tube (4) from the engine. Discard the tube O-ring. 13. Remove the six bracket bolts. 14. Lift and position the generator and the A/C compressor (along with their common mounting bracket) to gain access to the bypass hose. 15. Loosen and position both hose clamps to the center of the bypass hose. Remove the hose from vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Water Pump Inlet Tube - Removal > Page 2594 Coolant Line/Hose: Service and Repair Water Pump Inlet Tube - Installation WATER INLET TUBE 1. Position the bypass hose clamps to the center of the hose. 2. Install the bypass hose to the engine. 3. Secure both hose clamps. 4. Install the generator-A/C mounting bracket assembly to the engine. Tighten bolts (number 1 and 2 ) to 54 Nm (40 ft. lbs.). Tighten bolts (number 3 ) to 40 Nm (30 ft. lbs.). 5. Install a new O-ring to the heater hose return tube. Coat the new O-ring with antifreeze before installation. 6. Install the coolant return tube and its mounting bolt to engine. 7. Connect the throttle body control cables. 8. Install the oil dipstick mounting bolt. 9. Install the idler pulley. Tighten the bolt to 54 Nm (40 ft. lbs.). 10. Install the drive belt See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. 11. Install the air cleaner assembly See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body Installation. 12. Install the upper radiator hose to radiator. 13. Connect the wiring harness to the A/C compressor. 14. Connect the battery negative cable. 15. Fill the cooling system See: Service and Repair. 16. Start and warm the engine. Check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description Coolant Reservoir: Description and Operation Description COOLANT RECOVERY CONTAINER The coolant recovery container is integral to the windshield reservoir and is made of high temperature plastic. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Description and Operation > Description > Page 2599 Coolant Reservoir: Description and Operation Operation COOLANT RECOVERY CONTAINER The coolant recovery container works in conjunction with the radiator pressure cap. It utilizes thermal expansion and contraction of the coolant to keep the coolant free of trapped air. It provides a volume for expansion and contraction of the coolant. It also provides a convenient and safe method for checking the coolant level and adjusting the level at atmospheric pressure. This is done without removing the radiator pressure cap. The system also provides some reserve coolant to the radiator to cover minor leaks and evaporation or boiling losses. As the engine cools, a vacuum is formed in the cooling system of both the radiator and engine. Coolant is then drawn from the coolant tank and returned to a proper level in the radiator. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Bottle - Removal Coolant Reservoir: Service and Repair Coolant Recovery Bottle - Removal COOLANT RECOVERY CONTAINER 1. Disconnect the negative battery cable. 2. Disconnect the windshield waster hose (3). 3. Remove the overflow hose from the radiator. 4. Disconnect the washer pump electrical connector. 5. Remove the coolant recovery mounting bolts (4). 6. Remove the coolant recovery container (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Bottle - Removal > Page 2602 Coolant Reservoir: Service and Repair Coolant Recovery Bottle - Installation COOLANT RECOVERY CONTAINER 1. Position the coolant recover container (5). 2. Install the mounting bolts (4). Tighten the bolts (4) to 10 Nm (89 in. lbs.). 3. Connect the washer pump electrical connector. 4. Connect the washer hose (3). 5. Connect the overflow hose to the radiator. 6. Fill the coolant recover container See: Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Bottle - Removal > Page 2603 Coolant Reservoir: Service and Repair TPIM Coolant Recovery Container - Removal TPIM COOLANT RECOVERY RESERVOIR WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform HEV specific high voltage power down and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the negative battery cable. CAUTION: Disconnecting the 12 V battery from the vehicle within two minutes of the last ignition key transition from Off to Run may cause a Battery Pack Control Module (BPCM) State Of Charge (SOC) mismatch. 3. Drain the TPIM cooling system See: Service and Repair/TPIM Cooling System Draining NOTE: DO NOT spill coolant on electrical connections or connectors. 4. Remove the two lower coolant hoses (3). 5. Remove the coolant hose (4) at the coolant recovery container (2). 6. Remove the coolant recovery container mounting bolt. 7. Remove the TPIM coolant recovery container (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair > Coolant Recovery Bottle - Removal > Page 2604 Coolant Reservoir: Service and Repair TPIM Coolant Recovery Container - Installation TPIM COOLANT RECOVERY RESERVOIR WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Position the TPIM coolant recovery container (2) in the vehicle. 2. Install the mounting bolt. Tighten bolt to 10 Nm (88 in. lbs.). 3. Install the coolant hose (4) at the coolant recovery container (2) 4. Install the two lower coolant hoses (3). 5. Fill the TPIM cooling system See: Service and Repair/TPIM Cooling System Filling 6. Connect negative battery cable. 7. Perform HEV specific high voltage power up and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations > Page 2609 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Condenser Cooling Fan Module (Gas) (Headlamp And Dash) 3 Way Radiator Cooling Fan Control Module: Diagrams Condenser Cooling Fan Module (Gas) (Headlamp And Dash) 3 Way Connector (GAS) - (HEADLAMP AND DASH) 3 WAY FAN MODULE-CONDENSER COOLING (GAS) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Condenser Cooling Fan Module (Gas) (Headlamp And Dash) 3 Way > Page 2612 Radiator Cooling Fan Control Module: Diagrams HEV Radiator Cooling Fan Module (HEV) (Auxiliary Power Module) 4 Way Connector (HEV) - (AUXILIARY POWER MODULE) 4 WAY FAN MODULE-HEV RADIATOR COOLING (HEV) - (AUXILIARY POWER MODULE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations Radiator Cooling Fan Motor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations > Page 2616 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2619 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2620 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2621 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2622 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2623 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2624 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2625 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2626 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2627 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2628 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2629 Radiator Cooling Fan Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2630 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2631 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2632 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2633 Radiator Cooling Fan Motor: Connector Views Connector (GAS) - (HEADLAMP AND DASH) 3 WAY FAN MODULE-CONDENSER COOLING (GAS) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Radiator Fan High and Low Relays are located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan High Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan High Connector (IN IPM) RELAY-RADIATOR FAN HIGH (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan High > Page 2639 Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan Low Connector (IN IPM) RELAY-RADIATOR FAN LOW (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Resistor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Resistor > Component Information > Locations > Page 2643 Radiator Cooling Fan Resistor: Diagrams Connector - (HEADLAMP AND DASH) 2 WAY RESISTOR-RADIATOR FAN - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation > Viscous Radiator Fan Clutch - Description Fan Clutch: Description and Operation Viscous Radiator Fan Clutch - Description DESCRIPTION The thermal viscous fan drive (3) is a silicone fluid filled coupling used to connect the fan blades to the water pump shaft (4). The coupling allows the fan to be driven in a normal manner. This is done at low engine speeds while limiting the top speed of the fan to a predetermined maximum level at higher engine speeds. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation > Viscous Radiator Fan Clutch - Description > Page 2648 Fan Clutch: Description and Operation Viscous Radiator Fan Clutch - Operation OPERATION A thermostatic bimetallic spring coil (2) is located on the front face of the viscous fan drive unit (1). This spring coil reacts to the temperature of the radiator discharge air. It engages the viscous fan drive for higher fan speed if the air temperature from the radiator rises above a certain point. Until additional engine cooling is necessary, the fan will remain at a reduced rpm regardless of engine speed. Only when sufficient heat is present, will the viscous fan drive engage. This is when the air flowing through the radiator core causes a reaction to the bimetallic coil. It then increases fan speed to provide the necessary additional engine cooling. Once the engine has cooled, the radiator discharge temperature will drop. The bimetallic coil again reacts and the fan speed is reduced to the previous disengaged speed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Description and Operation > Page 2649 Fan Clutch: Testing and Inspection RADIATOR VISCOUS FAN NOISE NOTE: It is normal for fan noise to be louder (roaring) when: - The underhood temperature is above the engagement point for the viscous drive coupling. This may occur when the ambient (outside air temperature) is very high. - Engine loads and temperatures are high such as when towing a trailer. - Cool silicone fluid within the fan drive unit is being redistributed back to its normal disengaged (warm) position. This can occur during the first 15 seconds to one minute after engine start-up on a cold engine. LEAKS The viscous fan drive operation is not affected by small oil stains near the drive bearing. If leakage appears excessive, replace the fan drive unit. VISCOUS DRIVE If the fan assembly free-wheels without drag (the fan blades will revolve more than five turns when spun by hand), replace the fan drive. This spin test must be performed when the engine is cool. For the following test, the cooling system must be in good condition. It also will ensure against excessively high coolant temperature. WARNING: Be sure that there is adequate fan blade clearance before drilling. 1. Drill a 3.175 mm (1/8-in) diameter hole in the top center of the fan shroud. 2. Obtain a dial thermometer with an 203.8 mm (8 in.) stem. It should have a range of -18°-to-105°C (0°-to-220° F). Insert the thermometer through the hole in the shroud. Make sure that there is adequate clearance from the fan blades. 3. Connect a tachometer and an engine ignition timing light. The timing light is to be used as a strobe light. This step cannot be used on the diesel engine. 4. Block the air flow through the radiator. Secure a sheet of plastic in front of the radiator. Use tape at the top to secure the plastic and be sure that the air flow is blocked. 5. Be sure that the air conditioner (if equipped) and blow fan is turned off. WARNING: Use extreme caution when the engine is operating. Do not stand in a direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. 6. Start the engine and operate at 2400 rpm. Within ten minutes the air temperature (indicated on the dial thermometer) should be up to 88° C (190° F). Fan drive engagement should start to occur at/between: 3.7L - 90° C - 96°C (194° F - 205° F) - 4.7L - 93° - 98.8° C (200° - 210° F) - 5.7L - 96.6 - 102.2 °C (206°F - 216°F) - Engagement is distinguishable by a definite increase in fan flow noise (roaring). The timing light also will indicate an increase in the speed of the fan. 7. When viscous drive engagement is verified, remove the plastic sheet. Fan drive disengagement should start to occur at or between: - 3.7L - 76°C - 81°C (168° F - 178° F) - 4.7L - 67°C - 73°C (153° F - 163° F) - 5.7L - 56°C - 62°C (133° F - 143° F) A definite decrease of fan flow noise (roaring) should be noticed. If not, replace the defective viscous fan drive unit. CAUTION: If the viscous fan drive is replaced because of mechanical damage, the cooling fan blades should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could have resulted from excessive vibration. Replace fan blade assembly if any of these conditions are found. Also inspect water pump bearing and shaft assembly for any related damage due to a viscous fan drive malfunction. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Service and Repair > Procedures Fan Clutch: Procedures Cleaning CLEANING Clean the fan blades using a mild soap and water. Do not use an abrasive to clean the blades. Inspection INSPECTION WARNING: Do not attempt to bend or straighten fan blades if fan is not within specifications. CAUTION: If fan blade assembly is replaced because of mechanical damage, water pump and viscous fan drive should also be inspected. These components could have been damaged due to excessive vibration. 1. Remove fan blade assembly from viscous fan drive unit (four bolts). 2. Lay fan on a flat surface with leading edge facing down. With tip of blade touching flat surface, replace fan if clearance between opposite blade and surface is greater than 2.0 mm (.090 inch). Rocking motion of opposite blades should not exceed 2.0 mm (.090 inch). Test all blades in this manner. 3. Inspect fan assembly for cracks, bends, loose rivets or broken welds. Replace fan if any damage is found. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Service and Repair > Procedures > Page 2652 Fan Clutch: Removal and Replacement Viscous Radiator Fan Clutch - Removal RADIATOR VISCOUS FAN 1. Remove the air filter housing assemblySee: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Air Filter Element/Service and Repair/Air Cleaner - Removal. 2. Using Tool 6958 and Adapter pins 8346 (1), remove the fan/viscous fan drive assembly from the water pump. Do not attempt to remove the fan/viscous fan drive assembly from vehicle at this time. 3. Position the fan/fan drive assembly in the radiator shroud. 4. Remove the two shroud mounting screws. 5. Remove the radiator shroud and fan drive assembly. 6. After removing fan blade/viscous fan drive assembly, do not place the viscous fan drive in horizontal position. If stored horizontally, silicone fluid in the viscous fan drive could drain into its bearing assembly and contaminate lubricant. 7. Remove the four bolts securing the fan blade assembly to the viscous fan drive. Viscous Radiator Fan Clutch - Installation RADIATOR VISCOUS FAN 1. Install the fan blade assembly to the viscous fan drive. Tighten the bolts to 23 Nm (17 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Service and Repair > Procedures > Page 2653 2. Position the fan blade/viscous fan drive assembly into the radiator shroud. 3. Install the radiator shroud and the fan drive assembly into the vehicle. 4. Install fan shroud retaining screws. Tighten screws to 6 Nm (50 lbs. in.) 5. Using Tool 6958, install the fan blade/viscous fan drive assembly to the water pump shaft. Tighten mounting nut to 50 Nm (37 ft. lbs.). 6. Install the upper radiator hose. 7. Fill the cooling system See: Service and Repair. 8. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2658 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2659 Coolant Temperature Sensor/Switch (For Computer): Diagrams Connector - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Hybrid Drive Coolant Temperature Sensor > Component Information > Diagrams Hybrid Drive Coolant Temperature Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 2 WAY SENSOR-TPIM COOLANT TEMPERATURE (HEV) - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Hybrid Drive Coolant Temperature Sensor > Component Information > Diagrams > Page 2663 Hybrid Drive Coolant Temperature Sensor: Description and Operation TPIM COOLING SYSTEM TEMPERATURE SENSOR The TPIM cooling system temperature sensor (2) is used to sense the coolant temperature. The sensor (2) is located in the combination Transmission/TPIM cooler. The coolant sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. As the coolant temperature increases, resistance (voltage) in the sensor decreases. As the temperature decreases, resistance (voltage) in the sensor increases. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Hybrid Drive Coolant Temperature Sensor > Component Information > Service and Repair > TPIM Cooling System Temperature Sensor - Removal Hybrid Drive Coolant Temperature Sensor: Service and Repair TPIM Cooling System Temperature Sensor - Removal TPIM COOLING SYSTEM TEMPERATURE SENSOR WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform HEV specific high voltage power down and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the negative battery cable. CAUTION: Disconnecting the 12 V battery from the vehicle within two minutes of the last ignition key transition from Off to Run may cause a Battery Pack Control Module (BPCM) State Of Charge (SOC) mismatch. 3. Raise and support the vehicle. 4. Drain the TPIM cooling system See: Service and Repair/TPIM Cooling System Draining NOTE: DO NOT spill coolant on electrical connections or connectors. 5. Disconnect the temperature sensor electrical connector. 6. Remove the temperature sensor (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Hybrid Drive Coolant Temperature Sensor > Component Information > Service and Repair > TPIM Cooling System Temperature Sensor - Removal > Page 2666 Hybrid Drive Coolant Temperature Sensor: Service and Repair TPIM Cooling System Temperature Sensor - Installation TPIM COOLING SYSTEM TEMPERATURE SENSOR WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Install the temperature sensor (2) into the Transmission/TPIM cooler (1). 2. Tighten the sensor to 20 Nm (15 ft. lbs.). 3. Connect negative battery cable. 4. Perform HEV specific high voltage power up and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 5. Fill the TPIM cooling system and check for leaks. See: Service and Repair/TPIM Cooling System Filling Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Front Heater Core - Description Heater Core: Description and Operation Front Heater Core - Description DESCRIPTION The heater core (1) for the front heating-A/C system is located in the front HVAC housing, behind the instrument panel. It is a heat exchanger made of rows of tubes and fins. The heater core is secured to the HVAC housing by a plastic retaining bracket and screws. The heater core tubes (2) are attached to the top of the heater core by metal retaining clips (3) and O-ring seals. The heater core tubes are not serviced separately from the heater core. The HVAC housing must be removed from the vehicle to service the heater core. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Front Heater Core - Description > Page 2671 Heater Core: Description and Operation Front Heater Core - Operation OPERATION Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door(s) allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and must be replaced if restricted, leaking or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Front Heater Core - Description > Page 2672 Heater Core: Description and Operation Rear Heater Core - Description DESCRIPTION The rear heater core (1) is a heat exchanger made of rows of tubes and fins. The rear heater core is located in the rear heater-A/C housing behind the right interior quarter trim panel and is retained in the housing by a plastic mounting bracket and a screw. The heater core tubes (3) are attached to the heater core by metal retaining clamps (2) and rubber O-ring seals and are secured to the rear heater-A/C housing by a plastic flange. The heater core tubes are not serviced separately from the rear heater core. The rear heater-A/C housing must be removed from the vehicle to service the rear heater core. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Description and Operation > Front Heater Core - Description > Page 2673 Heater Core: Description and Operation Rear Heater Core - Operation OPERATION Engine coolant is circulated through heater hoses and tubes to the rear heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and the air directed through the heater core picks up the heat from the fins. The rear blend air door allows control of the rear heater output air temperature by controlling the amount of air flowing through or around the rear heater core. The rear blower motor speed controls the volume of air flowing through the rear heater-A/C housing. The rear heater core cannot be repaired and must be replaced if inoperative, leaking or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal Heater Core: Service and Repair Front Heater Core - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: The heater core tubes are not serviced separately from the heater core. The heater core tubes should not be repositioned, loosened or removed from the heater core. Failure to follow this warning could result in a coolant leak and possible serious or fatal injury. NOTE: Gasoline model shown in illustrations. HEV model similar. 1. Remove the front HVAC housing (1) and place it on a workbench See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal. 2. Disconnect the HVAC wire harness (2) from the recirculation door actuator (3). 3. Remove the screws (4) that secure the air inlet housing (5) to the HVAC housing. 4. Remove the air inlet housing from the HVAC housing. 5. Carefully remove the foam seal (1) from the flange on the HVAC housing (2). If the seal is deformed or damaged, it must be replaced. 6. Remove the screw (3) that secures the heater core tube retaining bracket (4) to the top of the HVAC housing. 7. Remove the heater core tube retaining bracket from the HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 2676 8. Remove the two screws (1) that secure the HVAC housing retaining bracket (2) to the top of the HVAC housing (3) and remove the bracket. 9. Remove the two screws (4) that secure the heater core retaining bracket (5) to the top of the HVAC housing and remove the bracket. 10. Carefully remove the heater core (6) and heater core tubes as an assembly from the top of the HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 2677 Heater Core: Service and Repair Front Heater Core - Installation INSTALLATION WARNING: The heater core tubes are not serviced separately from the heater core. The heater core tubes should not be repositioned, loosened or removed from the heater core. Failure to follow this warning could result in a coolant leak and possible serious or fatal injury. NOTE: Gasoline model shown in illustrations. HEV model similar. 1. Carefully install the heater core (6) into the top of the HVAC housing (3). Make sure that the heater core insulator is properly positioned. 2. Install the two screws (4) that secure the heater core retaining bracket (5) to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Install the HVAC housing bracket (2) to the top of HVAC housing. 4. Install the two screws (1) that secure the HVAC housing bracket to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Install the heater core tube retaining bracket (4) to the top of the HVAC housing (2). 6. Install the screw (3) that secures the heater core tube retaining bracket to the HVAC housing. Tighten the screw to 2.2 Nm (20 in. lbs.). 7. Install the foam seal (1) to the flange on the HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 2678 8. Install the air inlet housing (5) onto the top of the HVAC housing (1). 9. Install the screws (4) that secure the air inlet housing to the HVAC housing. Make sure the HVAC wire harness retainer is properly installed. 10. Connect the HVAC wire harness (2) to the recirculation door actuator (3). 11. Install the front HVAC housing See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Installation. 12. Reconnect the negative battery cable. 13. If the heater core is being replaced, flush the cooling system See: Service and Repair. 14. Refill the engine cooling system See: Service and Repair. 15. Evacuate the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Evacuate. 16. Charge the refrigerant system See: Heating and Air Conditioning/Service and Repair/Refrigerant System Charge. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 2679 Heater Core: Service and Repair Rear Heater Core - Removal REMOVAL WARNING: The heater core tubes are not serviced separately from the rear heater core. The heater core tubes should not be repositioned, loosened or removed from the rear heater core. Failure to follow this warning may result in a coolant leak and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the rear heater-A/C housing See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal. NOTE: If the foam seal for the flange is deformed or damaged, the seal be replaced. 3. Carefully remove the foam seal (3) from the rear heater core tube and evaporator line flange (2). 4. Remove the screw (4) that secures the rear heater core tube and evaporator line flange to the outboard side of the rear heater-A/C housing (5). 5. Disengage the retaining tab (1) that secures the rear heater core tube and evaporator line flange to the rear heater-A/C housing and remove the flange. 6. Remove the screw (3) that secures the rear heater core retaining bracket (4) to the rear heater-A/C housing (1) and remove the bracket. NOTE: If a foam seal around the heater core is deformed or damaged, the seal must be replaced. 7. Carefully pull the rear heater core (2) out of the inboard side of the rear heater-A/C housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 2680 Heater Core: Service and Repair Rear Heater Core - Installation INSTALLATION WARNING: The heater core tubes are not serviced separately from the rear heater core. The heater core tubes should not be repositioned, loosened or removed from the rear heater core. Failure to follow this warning may result in a coolant leak and possible serious or fatal injury. NOTE: If a foam seal on the rear heater core is deformed or damaged, the seal must be replaced. 1. Install the rear heater core (2) into the inboard side of the rear heater-A/C housing (1). Make sure that the foam seals around the heater core are properly installed. 2. Install the rear heater core retaining bracket (4). 3. Install the screw (3) that secures the rear heater core retaining bracket to the rear heater-A/C housing. Tighten the screw to 2 Nm (17 in. lbs.). 4. Position the rear heater core tube and evaporator line flange (2) to the outboard side of the rear heater-A/C housing (5) and engage the retaining tab (1). Make sure the tab is fully engaged to the housing. 5. Install the screw (4) that secures the rear heater core tube and evaporator line flange to the inboard side of the rear heater-A/C housing. Tighten the screw to 2 Nm (17 in. lbs.). NOTE: If the foam seal for the flange is deformed or damaged, the seal be replaced. 6. Carefully install the foam seal (3) onto the rear heater core tube and evaporator line flange. 7. Install the rear heater-A/C housing See: Heating and Air Conditioning/Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Installation. 8. Reconnect the negative battery cable. 9. If the rear heater core is being replaced, flush the cooling system See: Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Hybrid Drive Coolant Temperature Sensor > Component Information > Diagrams Hybrid Drive Coolant Temperature Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 2 WAY SENSOR-TPIM COOLANT TEMPERATURE (HEV) - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Hybrid Drive Coolant Temperature Sensor > Component Information > Diagrams > Page 2684 Hybrid Drive Coolant Temperature Sensor: Description and Operation TPIM COOLING SYSTEM TEMPERATURE SENSOR The TPIM cooling system temperature sensor (2) is used to sense the coolant temperature. The sensor (2) is located in the combination Transmission/TPIM cooler. The coolant sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. As the coolant temperature increases, resistance (voltage) in the sensor decreases. As the temperature decreases, resistance (voltage) in the sensor increases. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Hybrid Drive Coolant Temperature Sensor > Component Information > Service and Repair > TPIM Cooling System Temperature Sensor - Removal Hybrid Drive Coolant Temperature Sensor: Service and Repair TPIM Cooling System Temperature Sensor - Removal TPIM COOLING SYSTEM TEMPERATURE SENSOR WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform HEV specific high voltage power down and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the negative battery cable. CAUTION: Disconnecting the 12 V battery from the vehicle within two minutes of the last ignition key transition from Off to Run may cause a Battery Pack Control Module (BPCM) State Of Charge (SOC) mismatch. 3. Raise and support the vehicle. 4. Drain the TPIM cooling system See: Service and Repair/TPIM Cooling System Draining NOTE: DO NOT spill coolant on electrical connections or connectors. 5. Disconnect the temperature sensor electrical connector. 6. Remove the temperature sensor (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Hybrid Drive Coolant Temperature Sensor > Component Information > Service and Repair > TPIM Cooling System Temperature Sensor - Removal > Page 2687 Hybrid Drive Coolant Temperature Sensor: Service and Repair TPIM Cooling System Temperature Sensor - Installation TPIM COOLING SYSTEM TEMPERATURE SENSOR WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Install the temperature sensor (2) into the Transmission/TPIM cooler (1). 2. Tighten the sensor to 20 Nm (15 ft. lbs.). 3. Connect negative battery cable. 4. Perform HEV specific high voltage power up and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 5. Fill the TPIM cooling system and check for leaks. See: Service and Repair/TPIM Cooling System Filling Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Temperature Gauge - Description Temperature Gauge: Description and Operation Temperature Gauge - Description DESCRIPTION An engine coolant temperature gauge is standard equipment on all instrument clusters. This gauge is part of the minor gauge set with the fuel gauge located on the left side of the instrument cluster, just left of the speedometer. The gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree gauge scale on the cluster overlay that reads bottom-to-top from C (or Cold) to H (or Hot). An International Control and Display Symbol icon for Engine Coolant Temperature is located on the cluster overlay, directly below the bottom end of the scale. The engine coolant temperature gauge graphics are black against a white field except for a single red graduation at the high end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the white gauge dial face appears blue-green with the black graphics silhouetted against the illuminated background and the red graphics and the red gauge needle still appear red. Gauge illumination is provided by an integral electro-luminescent lamp that is serviced as a unit with the instrument cluster. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Temperature Gauge - Description > Page 2693 Temperature Gauge: Description and Operation Temperature Gauge - Operation OPERATION The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives an electronic engine temperature message from the PCM indicating the temperature is between the low end of normal [about 54 °C (130 °F)] and the high end of normal [about 122 °C (252 °F)], the gauge needle moves to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives an electronic engine temperature message from the PCM indicating the temperature is below the low end of normal [about 54 °C (130 °F)], the gauge needle is held at the C increment at the low end of the gauge scale. The gauge needle remains at the low end of the gauge scale until the cluster receives a message from the PCM indicating that the temperature is above about 54 °C (130 °F), or until the ignition switch turns to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives an electronic engine temperature message from the PCM indicating the temperature is above about 122 °C (252 °F), the gauge needle moves to the red zone at the high end of the gauge scale, the engine temperature indicator illuminates and a single chime tone is sounded. The gauge needle remains in the red zone and the engine temperature indicator remains illuminated until the cluster receives a message from the PCM indicating that the temperature is below about 122 °C (252 °F), or until the ignition switch turns to the OFF position, whichever occurs first. The chime tone feature only repeats during the same ignition cycle if the engine temperature indicator is cycled off then on again by the appropriate messages from the PCM. - Communication Error - If the cluster fails to receive an engine temperature message, it holds the gauge needle at the last indication for about five seconds or until the ignition switch turns to the OFF position, whichever occurs first. After five seconds, the cluster moves the gauge needle to the low end of the gauge scale. - Self Test - Each time the cluster is put through the self test, the engine coolant temperature gauge needle is swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM then sends the proper messages to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. If the instrument cluster turns on the engine temperature indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. Use a diagnostic scan tool for proper diagnosis of the engine coolant temperature sensor, the PCM, the CCN, the CAN data bus or the electronic communication related to engine coolant temperature gauge operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Engine Temperature Lamp - Description Temperature Warning Lamp/Indicator: Description and Operation Engine Temperature Lamp Description DESCRIPTION An engine temperature indicator is standard equipment on all instrument clusters. The engine temperature indicator is located near the upper edge of the instrument cluster, between the minor gauge set and the speedometer. The engine temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine Coolant Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The engine temperature indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Engine Temperature Lamp - Description > Page 2698 Temperature Warning Lamp/Indicator: Description and Operation Engine Temperature Lamp Operation OPERATION The engine temperature indicator gives an indication to the vehicle operator when the engine temperature gauge reading reflects a condition requiring immediate attention. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The engine temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the engine temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the on position the engine temperature indicator illuminates for about two seconds as a bulb test. The entire bulb test is a function of the PCM. - Engine Temperature High Message - Each time the cluster receives an electronic engine temperature message from the PCM indicating the temperature is above about 122 °C (252 °F), the engine temperature indicator illuminates and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the temperature is below about 119 °C (246 °F), or until the ignition switch is turned to the off position, whichever occurs first. The chime tone feature only repeats during the same ignition cycle if the engine temperature indicator is cycled off, then on again by the appropriate messages from the PCM. - Self Test - Each time the cluster is put through the self test, the engine temperature indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM then sends the proper messages to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the engine temperature indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. If the instrument cluster turns ON the engine temperature indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. Use a diagnostic scan tool for proper diagnosis of the engine coolant temperature sensor, the PCM, the CCN, the CAN data bus or the electronic communication related to engine temperature indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Description Radiator: Description and Operation Description RADIATOR The radiator is an aluminum vertical-flow design with vertical tubes through the radiator core, plastic top and the bottom tanks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Description > Page 2703 Radiator: Description and Operation Operation OPERATION The radiator supplies sufficient heat transfer using the cooling fins interlaced between the horizontal tubes in the radiator core to cool the engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Description and Operation > Page 2704 Radiator: Testing and Inspection RADIATOR COOLANT FLOW Use the following procedure to determine if the coolant is flowing through the cooling system. 1. Idle the engine until the operating temperature is reached. If the upper radiator hose is warm to the touch, the thermostat is opening and the coolant is flowing to the radiator. WARNING: Hot, pressurized coolant can cause injury by scalding. Using a rag to cover the radiator pressure cap, open the radiator cap slowly to first stop. Allow any built-up pressure to vent to the coolant recovery container. After the pressure build-up has been released, remove the cap from the filler neck. 2. Drain a small amount of coolant from the radiator until the ends of radiator tubes are visible through the filler neck. Idle the engine at normal operating temperature. If the coolant is flowing past exposed tubes, the coolant is circulating. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures Radiator: Procedures Cleaning RADIATOR Clean the radiator fins with the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or A/C condenser of debris. Inspection RADIATOR The radiator cooling fins should be checked for damage or deterioration. Inspect the cooling fins to make sure they are not bent or crushed. These areas result in reduced heat exchange capacity, causing the cooling system to operate at higher temperatures. Inspect the plastic end tanks for cracks, damage or leaks. Inspect the radiator neck for damage or distortion. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 2707 Radiator: Removal and Replacement Engine Cooling Radiator - Removal 5.7L HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform HEV specific high voltage power down and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the negative battery cable. CAUTION: Disconnecting the 12 V battery from the vehicle within two minutes of the last ignition key transition from Off to Run may cause a Battery Pack Control Module (BPCM) State Of Charge (SOC) mismatch. 3. Raise and support the vehicle. 4. Drain the coolant from the radiator.See: Service and Repair 5. Drain the TPIM cooling system. See: Service and Repair/TPIM Cooling System Draining 6. Disengage the transmission cooler lines (1) from the retainer clip located on radiator. 7. Remove the lower radiator hose (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 2708 8. Remove the lower transmission oil cooler to radiator screws. 9. Disconnect the power steering cooler lines (2). 10. Lower the vehicle. 11. Remove the pushpins (1) and the upper condenser/radiator seal (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 2709 12. Remove the air filter housing assembly.See: Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal 13. Remove the upper radiator support bracket bolts (2) and the upper radiator support bracket (3). 14. Remove the upper radiator hose. 15. Remove the overflow tube. 16. Remove the radiator cooling fan. See: Radiator Cooling Fan 17. Remove the upper transmission oil cooler to radiator screws. 18. Remove the LH and RH radiator side seals. 19. Remove the radiator by lifting up. Engine Cooling Radiator - Installation 5.7L HEV ENGINE WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Position the radiator in the vehicle. 2. Position the isolator pins into the alignment holes in the radiator lower support 3. Install the upper transmission oil cooler to radiator screws. 4. Install the upper radiator support bracket (3). Tighten the bolts (2) to 10 Nm (89 in. lbs.) 5. Install the LH and RH radiator side seals. 6. Install the upper radiator hose. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 2710 7. Install the overflow tube. 8. Install the electric cooling fan. See: Radiator Cooling Fan 9. Install the pushpins (1) and the upper condenser/radiator seal (2). 10. Raise the vehicle. 11. Install the lower transmission oil cooler to radiator screws. 12. Connect the power steering cooler lines (2). 13. Install the lower radiator hose (2). 14. Engage the transmission cooler lines (1) to the retainer clip located on radiator. 15. Lower the vehicle. 16. Install the air filter housing assembly. 17. Fill the radiator. 18. Fill the TPIM cooling system. See: Service and Repair/TPIM Cooling System Filling 19. Connect the battery negative cable. 20. Perform HEV specific high voltage power up and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 21. Start and warm the engine. Check for leaks.See: Testing and Inspection TPIM/Transmission Cooler - Removal COMBINATION TPIM/TRANSMISSION OIL COOLER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 2711 WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform HEV specific high voltage power down and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the negative battery cable. CAUTION: Disconnecting the 12 V battery from the vehicle within two minutes of the last ignition key transition from Off to Run may cause a Battery Pack Control Module (BPCM) State Of Charge (SOC) mismatch. 3. Drain the TPIM cooling system. See: Service and Repair/TPIM Cooling System Draining 4. Remove the coolant pump.See: Water Pump/Service and Repair/Removal and Replacement/TPIM Coolant Pump - Removal 5. Using Tool 9005, disconnect the transmission cooler lines (4). 6. Unclip the cooler lines (3) at radiator. 7. Disconnect the temperature sensor electrical connector. 8. Remove the coolant hose. 9. Remove the upper cooler mounting bolts. 10. Remove the upper cooler mounting bolts. 11. Remove the lower cooler mounting bolts. 12. Remove the Combination TPIM/Transmission Oil Cooler from bottom of the vehicle. TPIM/Transmission Cooler - Installation COMBINATION TPIM/TRANSMISSION OIL COOLER WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Service and Repair > Procedures > Page 2712 1. If removed, install the TPIM coolant temperature sensor. Tighten to 20 Nm (177 in. lbs.) 2. Position the Transmission/TPIM cooler. 3. Install the upper mounting bolts. 4. Install the lower mounting bolts 5. Tighten bolts to 8.5 Nm (75 in. lbs.). 6. Clip the transmission tubes (3) into the retainers (2) on bottom of the radiator. 7. Install the transmission cooler lines (4) onto the cooler tubes (3). 8. Install the coolant hose. 9. Connect the temperature sensor electrical connector. 10. Install the coolant pump See: Water Pump/Service and Repair/Removal and Replacement/TPIM Coolant Pump - Installation 11. Fill the cooling system See: Service and Repair/Cooling System Filling 12. Connect negative battery cable. 13. Perform HEV specific high voltage power up and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Radiator Cap - Description Radiator Cap: Description and Operation Radiator Cap - Description RADIATOR PRESSURE CAP All cooling systems are equipped with a pressure cap on the radiator. This cap releases pressure at some point within a range of 96.5 - 124 kPa (14 - 18 psi). The pressure relief point (in pounds) is engraved on top of the cap (3). The cooling system will operate at pressures slightly above atmospheric pressure. This results in a higher coolant boiling point allowing increased radiator cooling capacity. The cap contains a spring-loaded pressure relief valve (4). This valve opens when system pressure reaches the release range of 96.5 - 124 kPa (14 - 18 psi). A rubber gasket (2) seals the radiator filler neck. This is done to maintain vacuum during coolant cool-down and to prevent leakage when system is under pressure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Description and Operation > Radiator Cap - Description > Page 2717 Radiator Cap: Description and Operation Radiator Cap - Operation RADIATOR PRESSURE CAP A vent valve in the center of the cap will remain shut as long as the cooling system is pressurized. As the coolant cools, it contracts and creates a vacuum in cooling system. This causes the vacuum valve to open and the coolant in reserve/overflow tank to be drawn through the connecting hose into radiator. If the vacuum valve is stuck shut, or the overflow hose is kinked, the radiator hoses will collapse on cool-down. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Radiator Cap to Filler Neck Seal Radiator Cap: Testing and Inspection Radiator Cap to Filler Neck Seal RADIATOR CAP-TO-FILLER NECK SEAL The pressure cap upper gasket (seal) pressure relief can be tested by removing the overflow hose from the radiator filler neck nipple. Attach the hose of pressure tester tool 7700 (or equivalent) to nipple. It will be necessary to disconnect the hose from its adapter for the filler neck. Pump air into the radiator. The pressure cap upper gasket should relieve at 131 kPa (21 psi) and hold pressure at a minimum of 130 kPa (18.8 psi). WARNING: The warning words DO NOT OPEN HOT on radiator pressure cap, are a safety precaution. When hot, pressure builds up in cooling system. To prevent scalding or injury, radiator cap should not be removed while system is hot and/or under pressure. Do not remove the radiator cap at any time except for the following purposes: 1. Check and adjust the antifreeze freeze point. 2. Refill system with new antifreeze. 3. Conducting service procedures. 4. Checking for vacuum leaks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection > Radiator Cap to Filler Neck Seal > Page 2720 Radiator Cap: Testing and Inspection Radiator Pressure Cap RADIATOR CAP Remove cap (1) from radiator. Be sure that sealing surfaces are clean. Moisten rubber gasket with water and install cap (1) on pressure tester 7700 (2) or equivalent. Operate tester pump to bring pressure to 138 kPa (20 psi) on gauge. If pressure cap (1) fails to hold pressure of at least 131 kPa (19 psi) replace cap. Refer to the following CAUTION. The pressure cap may test properly while positioned on tool 7700 (or equivalent). It may not hold pressure or vacuum when installed on radiator. If so, inspect radiator filler neck and cap's top gasket for damage. Also inspect for dirt or distortion that may prevent cap from sealing properly. CAUTION: Radiator pressure testing tools are very sensitive to small air leaks, which will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool. Add water to tool. Turn tool upside down and recheck pressure cap to confirm that cap needs replacement. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Service and Repair > Radiator Cap - Cleaning Radiator Cap: Service and Repair Radiator Cap - Cleaning RADIATOR PRESSURE CAP Use only a mild soap and water to clean the radiator cap. Using any type solvent may cause damage to the seal in the radiator cap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Service and Repair > Radiator Cap - Cleaning > Page 2723 Radiator Cap: Service and Repair Radiator Cap - Inspection RADIATOR PRESSURE CAP Hold the cap at eye level, right side up. The vent valve at bottom of the cap should open. If the rubber gasket has swollen and prevents the vent valve from opening, replace the cap. Hold the cap at eye level, upside down. If any light can be seen between the vent valve and the rubber gasket, replace cap. Do not use a replacement cap that has a spring to hold the vent shut. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to the radiator filler neck top surface. Use of a proper cap will allow coolant return to radiator. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations > Page 2728 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Condenser Cooling Fan Module (Gas) (Headlamp And Dash) 3 Way Radiator Cooling Fan Control Module: Diagrams Condenser Cooling Fan Module (Gas) (Headlamp And Dash) 3 Way Connector (GAS) - (HEADLAMP AND DASH) 3 WAY FAN MODULE-CONDENSER COOLING (GAS) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Condenser Cooling Fan Module (Gas) (Headlamp And Dash) 3 Way > Page 2731 Radiator Cooling Fan Control Module: Diagrams HEV Radiator Cooling Fan Module (HEV) (Auxiliary Power Module) 4 Way Connector (HEV) - (AUXILIARY POWER MODULE) 4 WAY FAN MODULE-HEV RADIATOR COOLING (HEV) - (AUXILIARY POWER MODULE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Locations Radiator Cooling Fan Motor Relay: Locations Radiator Fan High and Low Relays are located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan High Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan High Connector (IN IPM) RELAY-RADIATOR FAN HIGH (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Motor Relay > Component Information > Diagrams > Relay-Radiator Fan High > Page 2737 Radiator Cooling Fan Motor Relay: Diagrams Relay-Radiator Fan Low Connector (IN IPM) RELAY-RADIATOR FAN LOW (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2743 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2744 Coolant Temperature Sensor/Switch (For Computer): Diagrams Connector - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Hybrid Drive Coolant Temperature Sensor > Component Information > Diagrams Hybrid Drive Coolant Temperature Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 2 WAY SENSOR-TPIM COOLANT TEMPERATURE (HEV) - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Hybrid Drive Coolant Temperature Sensor > Component Information > Diagrams > Page 2748 Hybrid Drive Coolant Temperature Sensor: Description and Operation TPIM COOLING SYSTEM TEMPERATURE SENSOR The TPIM cooling system temperature sensor (2) is used to sense the coolant temperature. The sensor (2) is located in the combination Transmission/TPIM cooler. The coolant sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. As the coolant temperature increases, resistance (voltage) in the sensor decreases. As the temperature decreases, resistance (voltage) in the sensor increases. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Hybrid Drive Coolant Temperature Sensor > Component Information > Service and Repair > TPIM Cooling System Temperature Sensor - Removal Hybrid Drive Coolant Temperature Sensor: Service and Repair TPIM Cooling System Temperature Sensor - Removal TPIM COOLING SYSTEM TEMPERATURE SENSOR WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform HEV specific high voltage power down and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the negative battery cable. CAUTION: Disconnecting the 12 V battery from the vehicle within two minutes of the last ignition key transition from Off to Run may cause a Battery Pack Control Module (BPCM) State Of Charge (SOC) mismatch. 3. Raise and support the vehicle. 4. Drain the TPIM cooling system See: Service and Repair/TPIM Cooling System Draining NOTE: DO NOT spill coolant on electrical connections or connectors. 5. Disconnect the temperature sensor electrical connector. 6. Remove the temperature sensor (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Hybrid Drive Coolant Temperature Sensor > Component Information > Service and Repair > TPIM Cooling System Temperature Sensor - Removal > Page 2751 Hybrid Drive Coolant Temperature Sensor: Service and Repair TPIM Cooling System Temperature Sensor - Installation TPIM COOLING SYSTEM TEMPERATURE SENSOR WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Install the temperature sensor (2) into the Transmission/TPIM cooler (1). 2. Tighten the sensor to 20 Nm (15 ft. lbs.). 3. Connect negative battery cable. 4. Perform HEV specific high voltage power up and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 5. Fill the TPIM cooling system and check for leaks. See: Service and Repair/TPIM Cooling System Filling Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Temperature Gauge - Description Temperature Gauge: Description and Operation Temperature Gauge - Description DESCRIPTION An engine coolant temperature gauge is standard equipment on all instrument clusters. This gauge is part of the minor gauge set with the fuel gauge located on the left side of the instrument cluster, just left of the speedometer. The gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree gauge scale on the cluster overlay that reads bottom-to-top from C (or Cold) to H (or Hot). An International Control and Display Symbol icon for Engine Coolant Temperature is located on the cluster overlay, directly below the bottom end of the scale. The engine coolant temperature gauge graphics are black against a white field except for a single red graduation at the high end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the white gauge dial face appears blue-green with the black graphics silhouetted against the illuminated background and the red graphics and the red gauge needle still appear red. Gauge illumination is provided by an integral electro-luminescent lamp that is serviced as a unit with the instrument cluster. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Temperature Gauge - Description > Page 2756 Temperature Gauge: Description and Operation Temperature Gauge - Operation OPERATION The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives an electronic engine temperature message from the PCM indicating the temperature is between the low end of normal [about 54 °C (130 °F)] and the high end of normal [about 122 °C (252 °F)], the gauge needle moves to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives an electronic engine temperature message from the PCM indicating the temperature is below the low end of normal [about 54 °C (130 °F)], the gauge needle is held at the C increment at the low end of the gauge scale. The gauge needle remains at the low end of the gauge scale until the cluster receives a message from the PCM indicating that the temperature is above about 54 °C (130 °F), or until the ignition switch turns to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives an electronic engine temperature message from the PCM indicating the temperature is above about 122 °C (252 °F), the gauge needle moves to the red zone at the high end of the gauge scale, the engine temperature indicator illuminates and a single chime tone is sounded. The gauge needle remains in the red zone and the engine temperature indicator remains illuminated until the cluster receives a message from the PCM indicating that the temperature is below about 122 °C (252 °F), or until the ignition switch turns to the OFF position, whichever occurs first. The chime tone feature only repeats during the same ignition cycle if the engine temperature indicator is cycled off then on again by the appropriate messages from the PCM. - Communication Error - If the cluster fails to receive an engine temperature message, it holds the gauge needle at the last indication for about five seconds or until the ignition switch turns to the OFF position, whichever occurs first. After five seconds, the cluster moves the gauge needle to the low end of the gauge scale. - Self Test - Each time the cluster is put through the self test, the engine coolant temperature gauge needle is swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM then sends the proper messages to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. If the instrument cluster turns on the engine temperature indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. Use a diagnostic scan tool for proper diagnosis of the engine coolant temperature sensor, the PCM, the CCN, the CAN data bus or the electronic communication related to engine coolant temperature gauge operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Engine Temperature Lamp - Description Temperature Warning Lamp/Indicator: Description and Operation Engine Temperature Lamp Description DESCRIPTION An engine temperature indicator is standard equipment on all instrument clusters. The engine temperature indicator is located near the upper edge of the instrument cluster, between the minor gauge set and the speedometer. The engine temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine Coolant Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The engine temperature indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Engine Temperature Lamp - Description > Page 2761 Temperature Warning Lamp/Indicator: Description and Operation Engine Temperature Lamp Operation OPERATION The engine temperature indicator gives an indication to the vehicle operator when the engine temperature gauge reading reflects a condition requiring immediate attention. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The engine temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the engine temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the on position the engine temperature indicator illuminates for about two seconds as a bulb test. The entire bulb test is a function of the PCM. - Engine Temperature High Message - Each time the cluster receives an electronic engine temperature message from the PCM indicating the temperature is above about 122 °C (252 °F), the engine temperature indicator illuminates and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the temperature is below about 119 °C (246 °F), or until the ignition switch is turned to the off position, whichever occurs first. The chime tone feature only repeats during the same ignition cycle if the engine temperature indicator is cycled off, then on again by the appropriate messages from the PCM. - Self Test - Each time the cluster is put through the self test, the engine temperature indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM then sends the proper messages to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the engine temperature indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. If the instrument cluster turns ON the engine temperature indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. Use a diagnostic scan tool for proper diagnosis of the engine coolant temperature sensor, the PCM, the CCN, the CAN data bus or the electronic communication related to engine temperature indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications TEMPERATURE RANGE On all engines the thermostat is closed below 90°C (195°F). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Engine Coolant Thermostat - Description Thermostat: Description and Operation Engine Coolant Thermostat - Description THERMOSTAT CAUTION: Do not operate an engine without a thermostat, except for servicing or testing. All engines use a wax pellet (3), reverse poppet choke type thermostat that controls the operating temperature of the engine by controlling the amount of coolant flow to the radiator. On all engines the thermostat is closed below 90°C (195°F). This provides for quick engine warm up and overall temperature control. The thermostat on the 5.7L engine is located beneath the thermostat housing (1) at the front of the intake manifold. The thermostat on the 3.7L/4.7L engines is located beneath the thermostat housing the lower LH front of the engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Engine Coolant Thermostat - Description > Page 2767 Thermostat: Description and Operation Engine Coolant Thermostat - Operation THERMOSTAT The wax pellet is located in a sealed container (3) at the spring end (4) of the thermostat. When heated, the pellet expands, overcoming the closing spring tension and water pump pressure to force the valve to open. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Description and Operation > Page 2768 Thermostat: Testing and Inspection ON-BOARD DIAGNOSTICS (OBD) All engines are equipped with On-Board Diagnostics (OBD) for certain cooling system components. If the powertrain control module (PCM) detects low engine coolant temperature, it will record a Diagnostic Trouble Code (DTC) in the PCM memory. Do not change a thermostat for lack of heat as indicated by the instrument panel gauge or by poor heater performance unless a DTC is present. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures for other probable causes. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Engine Coolant Thermostat - Removal Thermostat: Service and Repair Engine Coolant Thermostat - Removal 5.7L ENGINE 1. Disconnect the negative battery cable. 2. Drain the cooling system until the coolant level is below the thermostat See: Service and Repair 3. Remove the radiator hose (3) from the thermostat housing (1). 4. Remove the thermostat housing mounting bolts (2), thermostat housing (1), and thermostat. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Service and Repair > Engine Coolant Thermostat - Removal > Page 2771 Thermostat: Service and Repair Engine Coolant Thermostat - Installation 5.7L ENGINE 1. Clean the mating areas of the intake manifold and thermostat housing (1). 2. Install the thermostat into the recessed machined groove on the front cover. 3. Install the housing-to-front cover bolts. Tighten the bolts to 23 Nm (200 in. lbs.). 4. Install the radiator upper hose (3) to the thermostat housing (1). 5. Fill the cooling system See: Service and Repair. 6. Connect the negative battery cable. 7. Start and warm the engine. Check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications WATER PUMP Water Pump-to-Timing Chain Case Cover Bolts.........................................................................................................................................28 Nm (21 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2775 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2776 Water Pump: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 4 WAY PUMP-TPIM COOLING (HEV) - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Water Pump - Description Water Pump: Description and Operation Water Pump - Description 5.7L HEV ENGINE A centrifugal water pump (1) circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core. The pump is driven by a single drive belt that is driven by the crankshaft pulley. The water pump impeller is pressed onto the rear of a shaft that rotates in bearings pressed into the housing. The 5.7L HEV water pump also incorporates an internal electrically controlled clutch to improver warm up emissions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Water Pump - Description > Page 2779 Water Pump: Description and Operation Water Pump - Operation WATER PUMP A centrifugal water pump circulates coolant through the water jackets, passages, intake manifold, radiator core, cooling system hoses and heater core, this coolant absorbs the heat generated when the engine is running. The pump is driven by the engine crankshaft via a drive belt. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Water Pump - Description > Page 2780 Water Pump: Description and Operation TPIM Coolant Pump - Description TPIM COOLANT PUMP The TPIM coolant pump (5) is a 50 watt electric pump is used to circulate coolant through the TPIM (7) to remove heat built up by the high voltage converters in the TPIM assembly. Coolant is circulated through the combination transmission/TPIM (3) to dissipate this heat into the atmosphere. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Water Pump - Description > Page 2781 Water Pump: Description and Operation TPIM Coolant Pump - Operation TPIM COOLANT PUMP Coolant is drawn from the coolant recovery container (2) by the TPIM coolant pump (1). It flows through the combination transmission fluid/TPIM cooler through the TPIM back into the coolant recovery container. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Description and Operation > Page 2782 Water Pump: Testing and Inspection ON-BOARD DIAGNOSIS - (OBD) The HYBRID CONTROL PROCESSOR (HCP) has been programmed to monitor certain cooling system component.: If the problem is sensed in a monitored circuit often enough to indicated an actual problem, a DTC is stored. The DTC will be stored in the HCP memory for eventual display to the technician See: Powertrain Management/Computers and Control Systems/Testing and Inspection ACCESSING DIAGNOSTIC TROUBLE CODES To read DTCs and to obtain cooling system data, See: Powertrain Management/Computers and Control Systems/Testing and Inspection ERASING TROUBLE CODES After the problem has been repaired, use the scan tool to erase a DTC, Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures Water Pump: Procedures Water Pump - Coolant Air Evacuation COOLANT AIR EVACUATION Evacuating or purging air from the cooling system involves the use of a pressurized air operated vacuum generator. The vacuum created allows for a quick and complete coolant refilling while removing any air locks present in the system components. NOTE: To avoid damage to the cooling system, ensure that no component would be susceptible to damage when a vacuum is drawn on the system. WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL BASE COOLANT AND IS HARMFUL IF SWALLOWED OR INHALED. IF SWALLOWED, DRINK TWO GLASSES OF WATER AND INDUCE VOMITING. IF INHALED, MOVE TO FRESH AIR AREA. SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT STORE IN OPEN OR UNMARKED CONTAINERS. WASH SKIN AND CLOTHING THOROUGHLY AFTER COMING IN CONTACT WITH ETHYLENE GLYCOL. KEEP OUT OF REACH OF CHILDREN. DISPOSE OF GLYCOL BASED COOLANT PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE; PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED; PERSONAL INJURY CAN RESULT. WARNING: WEAR APPROPRIATE EYE AND HAND PROTECTION WHEN PERFORMING THIS PROCEDURE. NOTE: The service area where this procedure is performed should have a minimum shop air requirement of 80 PSI (5.5 bar) and should be equipped with an air dryer system. NOTE: For best results, the radiator should be empty. The vehicle's heater control should be set to the heat position (ignition may need to be turned to the on position but do not start the motor). 1. Refer to the Chrysler Penta star Service Equipment (Chrysler PSE) Coolant Refiller #85-15-0650 or equivalent tool's operating manual for specific assembly steps. 2. Choose an appropriate adapter cone that will fit the vehicle's radiator filler neck or reservoir tank. 3. Attach the adapter cone (2) to the vacuum gauge (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2785 4. Make sure the vacuum generator/venturi ball valve (3) is closed and attach an airline hose (2) (minimum shop air requirement of 80 PSI/5.5 bar) to the vacuum generator/venturi (1). 5. Position the adaptor cone/vacuum gauge assembly into the radiator filler neck or reservoir tank. Ensure that the adapter cone is sealed properly. 6. Connect the vacuum generator/venturi (2) to the positioned adaptor cone/vacuum gauge assembly (1). 7. Open the vacuum generator/venturi ball valve. NOTE: Do not bump or move the assembly as it may result in loss of vacuum. Some radiator overflow hoses may need to be clamped off to obtain vacuum. 8. Let the system run until the vacuum gauge shows a good vacuum through the cooling system. Refer to the tool's operating manual for appropriate pressure readings. NOTE: If a strong vacuum is being created in the system, it is normal to see the radiator hoses to collapse. 9. Close the vacuum generator/venturi ball valve. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2786 10. Disconnect the vacuum generator/venturi and airline from the adaptor cone/vacuum gauge assembly. 11. Wait approximately 20 seconds, if the pressure readings do not move, the system has no leaks. If the pressure readings move, a leak could be present in the system and the cooling system should be checked for leaks and the procedure should be repeated. 12. Place the tool's suction hose into the coolant's container. NOTE: Ensure there is a sufficient amount of coolant, mixed to the required strength/protection level available for use. For best results and to assist the refilling procedure, place the coolant container at the same height as the radiator filler neck. Always draw more coolant than required. If the coolant level is too low, it will pull air into the cooling system which could result in air locks in the system. 13. Connect the tool's suction hose (1) to the adaptor cone/vacuum gauge assembly (2). 14. Open the suction hose's ball valve to begin refilling the cooling system. 15. When the vacuum gauge reads zero, the system is filled. NOTE: On some remote pressurized tanks, it is recommended to stop filling when the proper level is reached. 16. Close the suction hose's ball valve and remove the suction hose from the adaptor cone/vacuum gauge assembly. 17. Remove the adaptor cone/vacuum gauge assembly from the radiator filler neck or reservoir tank. 18. With heater control unit in the HEAT position, operate engine with container cap in place. 19. After engine has reached normal operating temperature, shut engine off and allow it to cool. When engine is cooling down, coolant will be drawn into the radiator from the pressure container. 20. Add coolant to the recovery bottle/container as necessary. Only add coolant to the container when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion. Add necessary coolant to raise container level to the COLD MINIMUM mark after each cool down period. 21. Once the appropriate coolant level is achieved, attach the radiator cap or reservoir tank cap. Water Pump - Cleaning WATER PUMP Clean the gasket mating surface. Use caution not to damage the gasket sealing surface. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2787 To ensure proper gasket sealing, surface preparation must be performed, especially with the use of aluminum engine components. Never use the following to clean gasket surfaces: - Metal scraper. - Abrasive pad or paper to clean cylinder block and head. - High speed power tool with an abrasive pad or a wire brush). - High speed power tool with 3M Roloc(TM) Bristle Disc (white or yellow). Only use the following for cleaning gasket surfaces: - Solvent or a commercially available gasket remover - Plastic or wood scraper. Water Pump - Inspection WATER PUMP Inspect the water pump assembly for cracks in the housing, water leaks from the shaft seal, worn bearing or the impeller rubbing either the pump body or the timing chain case/cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2788 Water Pump: Removal and Replacement Water Pump - Removal 5.7L ENGINE - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform HEV specific high voltage power down and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the negative battery cable. CAUTION: Disconnecting the 12 V battery from the vehicle within two minutes of the last ignition key transition from Off to Run may cause a Battery Pack Control Module (BPCM) State Of Charge (SOC) mismatch. 3. Raise and support the vehicle. 4. Drain the coolant from the radiator.See: Service and Repair 5. Remove the lower radiator hose from the water pump (2). 6. Disconnect the heater hoses from the water pump fittings (3). 7. Remove the accessory drive belt.See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal 8. Remove the lower water pump (2) bolts (5 total). 9. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2789 10. Remove pushpins (1) and the upper condenser/radiator seal (2). 11. Remove the upper radiator support bracket bolts (2) and the upper radiator support bracket (3). 12. Remove the upper radiator hose. 13. Remove the EGR tube at the throttle body. 14. Remove the throttle body assembly.See: Powertrain Management/Fuel Delivery and Air Induction/Throttle Body/Service and Repair/Throttle Body - Removal 15. Disconnect the A/C compressor high voltage cables at the TIPM module. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Hybrid Battery Bus / Cable/Service and Repair/High Voltage Battery Cable - Removal 16. Disconnect the electrical connector from the ECT sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2790 17. Remove the upper radiator hose from the thermostat housing (4). 18. Remove the thermostat housing (4) and thermostat from the water pump (2).See: Thermostat/Service and Repair/Engine Coolant Thermostat Removal 19. Remove the water pump upper mounting bolts (7 total, 6 bolts and 1 stud). 20. Remove the water pump assembly (2). Water Pump - Installation 5.7L HEV ENGINE WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Clean gasket services. 2. Install the water pump (2) and the upper mounting bolts and stud (7 total, 6 bolts and 1 stud). Tighten the mounting bolts and stud to 28 Nm (21ft. lbs.). 3. Install the heater hoses to the water pump fittings (3). 4. Inspect the thermostat/seal assembly for damage, replace if necessary. 5. Install the thermostat and thermostat housing (4) to the water pump (2). Tighten the mounting bolts to 28 Nm (21ft. lbs.). 6. Install the upper radiator hose to the thermostat housing (4). 7. Connect the electrical connector to the ECT sensor (1). 8. Connect the A/C compressor high voltage cables. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Hybrid Battery Bus / Cable/Service and Repair/High Voltage Battery Cable - Installation 9. Install the throttle body assembly.See: Powertrain Management/Fuel Delivery and Air Induction/Throttle Body/Service and Repair/Throttle Body Installation 10. Install the EGR tube at the throttle body. 11. Connect the upper radiator hose. 12. Install the upper radiator support bracket (3). Tighten the bolts (2) to 10 N-m (89 in. lbs). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2791 13. Install the upper condenser/radiator seal (2) and pushpins (1). 14. Raise and support the vehicle. 15. Install the lower water pump (2) mounting bolts (5 total). Tighten the mounting bolts to 28 Nm (21ft. lbs.). 16. Install the accessory drive belt.See: Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation 17. Install the heater hoses (3) to the water pump (2). 18. Install the lower radiator hose to the water pump (2). 19. Evacuate air and refill cooling system.See: Procedures/Water Pump - Coolant Air Evacuation 20. Connect negative battery cable. 21. Perform HEV specific high voltage power up and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 22. Check cooling system for leaks.See: Testing and Inspection TPIM Coolant Pump - Removal TPIM COOLANT PUMP Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2792 WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform HEV specific high voltage power down and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the negative battery cable. CAUTION: Disconnecting the 12 V battery from the vehicle within two minutes of the last ignition key transition from Off to Run may cause a Battery Pack Control Module (BPCM) State Of Charge (SOC) mismatch. 3. Raise and support the vehicle. 4. Drain the TPIM cooling system See: Service and Repair/TPIM Cooling System Draining 5. Disconnect the coolant pump electrical connector (1). 6. Remove the coolant line (3). 7. Remove the coolant line (5). 8. Remove the coolant pump mounting bolts (2). 9. Remove the coolant pump and bracket (1) from the vehicle. TPIM Coolant Pump - Installation TPIM COOLANT PUMP Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Procedures > Page 2793 WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Position the coolant pump and bracket (1) on lower radiator. 2. Install the mounting bolts (2). Tighten bolts (2) to 8.6 Nm (75 in. lbs.) 3. Install the coolant line (5). 4. Install the coolant line (3). 5. Connect the coolant pump electrical connector (1). 6. Lower vehicle. 7. Connect negative battery cable. 8. Perform HEV specific high voltage power up and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 9. Fill the TPIM cooling system and check for leaks. See: Service and Repair/TPIM Cooling System Filling Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Description Catalytic Converter: Description and Operation Description DESCRIPTION All vehicles incorporate toeboard catalytic converters into the exhaust system. These catalytic converters are made of stainless steel designed to operate at extremely high temperatures. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Description > Page 2799 Catalytic Converter: Description and Operation Operation OPERATION The catalytic converter captures and burns any unburned fuel mixture exiting the combustion chambers during the exhaust stroke of the engine. This process aids in reducing emissions output. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 2800 Catalytic Converter: Testing and Inspection INSPECTION Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of overheating. If the converter has a heat shield attached make sure it is not bent or loose. If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter - Removal Catalytic Converter: Service and Repair Catalytic Converter - Removal 5.7L HEV To remove the RH catalytic converter it is necessary to remove the transmission. 1. Disconnect negative batter cable. 2. Raise and support the vehicle. 3. Saturate all exhaust bolts and nuts with Mopar(R) Rust Penetrant. Allow 5 minutes for penetration. 4. Disconnect the oxygen sensor electrical connectors. 5. Remove the clamp (3) holding the LH catalytic converter (4) to the RH catalytic converter (2). 6. Remove the catalytic converter-to-manifold bolts (1). 7. Remove the LH catalytic converter (4) from the RH catalytic converter (2). 8. Remove the transmission See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement/Removal. 9. Remove the clamp holding the RH catalytic converter (2) to the exhaust pipe(s). 10. Remove the RH catalytic converter (2) from the extension pipe. 11. Remove the RH catalytic converter from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter - Removal > Page 2803 Catalytic Converter: Service and Repair Catalytic Converter - Installation 5.7L HEV The band clamps are not reusable. After removal, the must be replaced. 1. Remove any burrs from the RH (2) and LH (4) catalytic converter. 2. Position RH catalytic converter to exhaust manifold. 3. Install catalytic converter to manifold bolts and nuts. Hand tighten at this time. 4. Install transmission See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement/Installation. 5. Position new RH catalytic converter-to-exhaust pipe clamp on exhaust pipe. Insert the RH (2) catalytic converter into the exhaust pipe. Do not tighten clamp at this time. 6. Make sure the alignment tang is seated in the alignment slot. 7. Position new RH catalytic converter-to-LH catalytic converter clamp on RH catalytic converter. Insert the LH catalytic converter (4) into the RH catalytic converter (2). Do not tighten clamp at this time. 8. Make sure the alignment tang is seated in the alignment slot. 9. Install the LH and RH catalytic converters (2 and 4) to the exhaust manifold. Install bolts. Do not tighten at this time. 10. Connect the oxygen sensor electrical connectors. 11. Make sure the catalytic converter assembly (2 and 4) are correctly positioned and the properly aligned. The minimum clearance between components is 25mm (1 inch). Ensure that the exhaust crossover has at least 15mm (.59 in.) clearance at transmission crossmember. Ensure that muffler isolators are not stretched. Measurement between insulator rods is approximately 42mm (1.65 in.). Make the necessary adjustments, if necessary. 12. 10. Tighten manifold flange bolts to 34 Nm (24 lbs. ft.). Tighten the new exhaust clamps to 61 Nm (45 lbs. ft). 13. Start the engine, inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications EXHAUST MANIFOLD Exhaust Manifold-to-Cylinder Head...................................................................................................... ......................................................25 Nm (18 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Description and Operation > Exhaust Manifold - Description Exhaust Manifold: Description and Operation Exhaust Manifold - Description DESCRIPTION The exhaust manifolds are log style with a patented flow enhancing design to maximize performance. The exhaust manifolds are made of high silicon molybdenum cast iron. A multi-layer stainless steel exhaust manifold gasket is used to improve sealing to the cylinder head. The exhaust manifolds are covered by a three layer laminated heat shield for thermal protection and noise reduction. The heat shields are fastened with a torque prevailing nut that is backed off slightly to allow for the thermal expansion of the exhaust manifold, with the exception of the nut, which also secures the oil dipstick tube bracket. That nut should not be backed off. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Description and Operation > Exhaust Manifold - Description > Page 2809 Exhaust Manifold: Description and Operation Exhaust Manifold - Operation OPERATION The exhaust manifolds collect the engine exhaust exiting the combustion chambers, then channels the exhaust gases to the exhaust pipes attached to the manifolds. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures Exhaust Manifold: Procedures Exhaust Manifold - Cleaning CLEANING Clean mating surfaces on cylinder head and manifold. Wash with solvent and blow dry with compressed air. Exhaust Manifold - Inspection INSPECTION Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness with a straight edge. Gasket surfaces must be flat within 0.2 mm per 300 mm (0.008 inch per foot). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2812 Exhaust Manifold: Removal and Replacement Exhaust Manifold - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform high voltage power down . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Remove the Traction Power Inverter Module (1). 3. Install Engine Support Fixture 8534B. 4. Raise vehicle. 5. Remove exhaust pipe to manifold bolts. 6. Remove engine mount through bolts. 7. Lower vehicle. 8. Raise engine enough to remove manifolds. CAUTION: Do not damage engine harness while raising the engine. 9. Remove heat shield. 10. Remove manifold bolts. 11. Remove manifold and gasket. Exhaust Manifold - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2813 1. Position the exhaust manifold gasket and exhaust manifold. 2. Install the manifold bolts and tighten to 25 Nm (18 ft. lbs.). 3. Install heat shield and tighten the retaining nuts to 8 Nm (70 in. lbs.). 4. Lower the engine. CAUTION: Do not damage engine harness while lowering the engine. 5. Remove the engine support fixture 8534B. 6. Raise and support the vehicle. 7. Install and tighten the right and left side engine mount through bolts. 8. Install the exhaust flange to pipe bolts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Procedures > Page 2814 9. Lower the vehicle. 10. If removed, install the Traction Power Inverter Module (TPIM) (1) See: Hybrid Drive Systems/Power Control System/Voltage Inverter/Service and Repair/Traction Power Inverter Module - Installation 11. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Description and Operation > Exhaust Tailpipe - Description Exhaust Pipe: Description and Operation Exhaust Tailpipe - Description DESCRIPTION The tailpipe is made of stainless steel and attaches to the muffler. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Description and Operation > Exhaust Tailpipe - Description > Page 2819 Exhaust Pipe: Description and Operation Exhaust Tailpipe - Operation OPERATION The tailpipe channels the exhaust out of the muffler and out from under the vehicle to control noise and prevent exhaust gas fumes from entering the passenger compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Description and Operation > Page 2820 Exhaust Pipe: Testing and Inspection INSPECTION Discard rusted clamps, broken or worn supports and attaching parts. Replace a component with original equipment parts, or equivalent. This will assure proper alignment with other parts in the system and provide acceptable exhaust noise levels. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Tailpipe - Removal Exhaust Pipe: Service and Repair Exhaust Tailpipe - Removal REMOVAL WARNING: If torches are used when working on the exhaust system, wear protective eye covering and do not allow the flame near the fuel lines. 1. Raise and support the vehicle. 2. Saturate the bolts and nuts with Mopar(R) Rust Penetrant. Allow 5 minutes for penetration. 3. Remove the exhaust pipe-to-muffler clamp (3). 4. Grind any tack weld, if present. 5. Remove the exhaust pipe insulators (1). 6. Remove the rear muffler insulators (5) if necessary. 7. If necessary, heat the connection with an oxygen/acetylene torch and twist tailpipe out of muffler. 8. Remove the exhaust pipe (2) from the muffler (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair > Exhaust Tailpipe - Removal > Page 2823 Exhaust Pipe: Service and Repair Exhaust Tailpipe - Installation INSTALLATION NOTE: The band clamps are not reusable. After removal, they must be replaced. 1. Remove any burrs from the exhaust pipe (2). 2. Connect the exhaust pipe (2) to the muffler (4). 3. Make sure that the alignment tang is seated in the alignment slot. 4. Install the muffler-to-exhaust pipe clamp. Do not tighten at this time. 5. Install the rear muffler insulators (5), if removed. 6. Install the tail pipe insulators (1) 7. Check the exhaust system for contact with the body panels. Make the necessary adjustments, if necessary. 8. Tighten muffler-to-exhaust pipe clamp to 61 Nm (45 ft. lbs.). 9. Lower the vehicle. 10. Start the engine, inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Description Heat Shield: Description and Operation Description DESCRIPTION There are two types of heat shields (1) used. One is stamped steel the other is molded foil sheets. The shields attach to the vehicle around the exhaust system. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Description and Operation > Description > Page 2828 Heat Shield: Description and Operation Operation OPERATION The heat shields prevent heat from the exhaust system from entering the passenger area and other areas where the heat can cause damage to other components. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal Heat Shield: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the screws and nuts holding the heat shields (1) to the frame and floor pan. 3. Slide the heat shield (1) out around the exhaust system. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Service and Repair > Removal > Page 2831 Heat Shield: Service and Repair Installation INSTALLATION 1. Position the heat shields to the floor pan or the frame and install the screws and nuts. 2. Tighten the screws/nuts to 7 Nm (60 in. lbs.). 3. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Description and Operation > Description Muffler: Description and Operation Description DESCRIPTION All engines use a stainless steel muffler (5) to control exhaust noise levels and exhaust back pressure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Description and Operation > Description > Page 2836 Muffler: Description and Operation Operation OPERATION The muffler is designed to muffle the sound of the exhaust as it leaves the engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal Muffler: Service and Repair Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the tail pipe See: Exhaust Pipe/Service and Repair/Exhaust Tailpipe - Removal. 3. Remove the muffler-to-catalytic converter clamp (3). 4. Remove the muffler isolators (1 and 4). 5. Remove the muffler (5) from the catalytic converter. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Removal > Page 2839 Muffler: Service and Repair Installation INSTALLATION NOTE: The band clamps are not reusable. After removal, they must be replaced. 1. Install the muffler to the catalytic converter or exhaust pipe. 2. Make sure the alignment tang seats in the alignment slot. 3. Install new exhaust clamps. Do not tighten at this time. 4. Install the muffler isolators. Make sure the muffler isolators are not stretched. The measurement between the hangers should be 42mm (1.65 in.). 5. Align the muffler and the exhaust pipe. Tighten the exhaust clamp nuts to 61 Nm (45 ft. lbs.). 6. Check the exhaust system for contact with body panels. Make the necessary adjustments, if necessary. 7. Lower the vehicle. 8. Start engine and check for exhaust leaks. Repair exhaust leaks as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Locations Battery, Hybrid Drive: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Locations > Page 2845 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Diagrams > Battery Pack Assembly C1 (HEV) (Body) 18 Way Battery, Hybrid Drive: Diagrams Battery Pack Assembly C1 (HEV) (Body) 18 Way Connector C1 (HEV) - (BODY) 18 WAY ASSEMBLY-BATTERY PACK (HEV) - (BODY) 18 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Diagrams > Battery Pack Assembly C1 (HEV) (Body) 18 Way > Page 2848 Battery, Hybrid Drive: Diagrams Battery Pack Assembly C2 (HEV) (Body) 2 Way Connector C2 (HEV) - (BODY) 2 WAY ASSEMBLY-BATTERY PACK (HEV) - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Description and Operation > High Voltage Battery - Description Battery, Hybrid Drive: Description and Operation High Voltage Battery - Description 300V The 300 Volt high voltage battery pack: - stores electrical energy for use by the Hybrid Electric Vehicle (HEV) system and system components - weighs 70 kg (150 lbs) - has a nominal voltage of 288 Volts - is packaged under the second row seats The high voltage battery pack case, includes the following components on the external portion: - A high voltage service disconnect - A high voltage terminal lugs - A battery gas vent tube - A battery cooling intake grate - A battery cooling exhaust duct - A low voltage connector The high voltage battery pack includes the following components: - A Battery Pack Control Module (BPCM) - contactors (similar to relays): - pre-charge - positive - negative - 40 - 7.2-volt battery modules - six temperature sensors - A current sensor - A cooling fan Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Description and Operation > High Voltage Battery - Description > Page 2851 Battery, Hybrid Drive: Description and Operation High Voltage Battery - Operation 300V BATTERY PACK The HEV battery contains 240, 1.2-Volt Nickel-Metal Hydride cells. These cells are in modules of six cells each, connected in series. You should see: - 300-310 Volts at 60% State of Charge (SOC) with contactors open. - 240-390 Volts during normal operation. - 216 Volts during worst case, cold cranking. - 60% +/- 8% State of Charge (SOC). - 358 Volts is upper limit during jump assist. BATTERY PACK CONTROL MODULE (BPCM) The BPCM communicates on the Hybrid Local Area Network (LAN) with the HCP, the Transmission Electro-Hydraulic Control Module (TEHCM), Accessory Power Module (APM) and Hybrid Gateway Module (HGM). The HGM also sends messages from the BPCM across the CAN-C network for use by other modules. Most BPCM communications are with the HCP. As the HCP controls the hybrid drivetrain, the BPCM make sure that the HV battery pack can supply the necessary HV current so that the vehicle can be driven. The BPCM notifies the HCP that current from the battery pack should be limited because of battery temperature or SOC. The BPCM controls the functions of the HV Battery Pack. The BPCM provides control outputs to: - Positive and Negative Contactors - Pre-Charge Contactor - HV Battery Cooling Fan - HVIL Source Current The BPCM monitors the following inputs: - Hybrid LAN Messages - HV Module Voltages (20 Inputs) - Total HV Battery Voltage - HV Battery Current - HVIL Circuit Current - Battery Pack Isolation Resistance (Measured Impedance) HIGH VOLTAGE INTERLOCK CIRCUIT (HVIL) The HVIL circuit helps prevent access to high voltage. The BPCM provides an output current across the HVIL circuit and monitors the return current to verify the integrity of the HVIL circuit. Both the current drivers and return current can be read with the scan tool. Both readings should be approximately 12mA. The BPCM contains the current drivers that provide the source current for the HVIL circuit. The HVIL circuit routes in series from the BPCM through the HVIL connectors at the HV components. - The circuit passes through a connector near the bulkhead and another connector under hood to the HVIL connector over the TPIM cover bolts. - From this connector, the circuit enters the HCP through the 56-pin connector on the front of the TPIM. - From the 56-pin connector, the circuit goes through a connector on the air cleaner duct. - The circuit then goes to the EVT HV cover HVIL connector. - From the EVT HVIL connector the circuit goes to the EAC connector. - From the EAC connector the circuit routes back to the BPCM through the under hood connector and the connector near the bulkhead. The HVIL circuit routes through the HCP in the TPIM. The HCP also monitors the HVIL current with solid-state circuitry. The BPCM can detect a, open circuit, short to ground and short to power failures on the HVIL circuit. A distinct DTC sets for each type of failure and is reported to the HCP. This illuminates the HEV service lamp and disables the HV system. This results in a no-start condition and disables the vehicle if the vehicle is operating at the time. If an HVIL circuit fault indicates, the HVIL circuit is diagnosed by measuring the resistance across the segments of the circuit. By measuring segments, the fault is narrowed down to a specific section of the circuit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Description and Operation > High Voltage Battery - Description > Page 2852 CONTACTORS The 12-Volt system, connects and disconnects the HV battery from the remainder of the HV system through heavy-duty relays called contactors. There is a positive and negative contactor connected to the positive and negative side of the battery. These contactors are normally open and must have reliable 12-Volt power to keep them closed. If the 12-Volt supply to the HV battery is intermittent, this may cause the contactors to open momentarily and then close. This can cause an arc across the contactor surfaces that can weld closed the contactor. If this happens, the 12-Volt system cannot control the HV system and the HV system remains energized. Contactor failures set a DTC and illuminates the HEV Service Lamp. PRE-CHARGE COMPONENTS Pre-charge components control voltage and current applied to the HV system. The initial application of current or in-rush of current, could damage the HV system if not controlled. To control the current application, a large resister is used when the HV system is initially powered up. The pre-charge components consist of the pre-charge resister, a pre-charge contactor and the required wiring to connect the components. The negative contactor is used during the pre-charge routine. To perform the pre-charge routine, the BPCM commands the pre-charge contactor and the negative contactor to close. The pre-charge resistor is in series on the circuit with the pre-charge contactor so this controls the power applied to the HV system. After the pre-charge and negative contactors close and apply partial voltage to the HV system, the BPCM commands the positive contactor to close. This creates a circuit with very little resistance compared to the pre-charge circuit. After the positive contactor has closed, the BPCM opens the pre-charge contactor. The HV system is now fully enabled and ready for operation. HIGH VOLTAGE BATTERY COOLING FAN As the HV system charges and discharges the HV battery, significant heat is created. To control the temperature of the battery, a 12-Volt fan located on the passenger side of the battery pack, pulls air across the battery components. The battery modules have spaces between them to allow airflow. Airflow also cools the contactors, BPCM and pre-charge resister on the driver side of the battery case. The cooling air passes around the carpeted beauty cover over the battery case and then enters the battery through an intake grate on the passenger side of the case. All airflow from the battery case is blown out of the case through an exhaust vent and exits under the vehicle. The intake grate for the cooling air is in a protected position under the battery cover. This area must be kept clear so that air can enter the battery with no restriction. The fan speed can be commanded though the scan tool under the BPCM miscellaneous function menu. This is an easy way to confirm operation of the fan. The BPCM controls the fan under direction from the HCP. The BPCM modulates the fan speed in response to battery temperature. The BPCM activates the fan: - Under 25°C (77°F), the cooling fan is not needed. - 25°C (77°F) to 50°C (122°F), the fan runs up to the maximum RPM allowed by the HCP. - Over 50°C (122°F), the fan runs at maximum RPM. - Over 60°C (140°F), the BPCM requests HV battery shut down from the HCP. The HCP limits the speed of the fan according to vehicle speed, HVAC blower speeds and engine RPM, to reduce Noise Vibration and Harshness (NVH) concerns. If the battery temperature exceeds 50°C (122°F), the fan runs at maximum speed. The fan does not run if the air inlet temperature is higher than the battery cell temperatures, to prevent hot air from entering the battery case. This may be the case if the vehicle sits for a long time in direct sunlight. The BPCM runs the fan intermittently and rechecks the temperature readings after circulating air. The fan is Pulse Width Modulated (PWM) on the ground side of the fan motor circuit. Any time the battery cooling fan is running, the fan removes air from the interior of the vehicle. As a result, air flows through the HVAC vents if all windows are closed. This is normal and the recirculation door in the HVAC system is designed with adequate fresh air access under all conditions. THERMISTORS There are six thermistors used to read temperature throughout the battery pack. Four are in the battery modules, to give a sample of battery cell temperatures. Two sensors read air inlet and air outlet temperatures. These readings are inputs to the BPCM and are used to determine desired fan speed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Description and Operation > High Voltage Battery - Description > Page 2853 The maximum and minimum temperatures from the six thermistors can be read using the scan tool. You cannot read all six temperatures or determine which sensor is the maximum or minimum reading. If a sensor fails, a DTC is set. Follow the proper service procedures. The thermistors must be replaced as an assembly with all of the thermistors and harness to the BPCM. This harness also includes the connector to the battery current sensor. VENT TUBES During heavy charging or discharging conditions, the battery modules may vent hydrogen gas because of high battery temperature. This off-gassing is captured through two battery vent tubes connected to vent ports on each module. The two tubes are connected together with a "T" fitting that is vented to the atmosphere under the vehicle. This vent tube is separate from the cooling air intake and exhaust vents. During normal operation there should be no off-gassing of hydrogen. CURRENT SENSOR An inductive current sensor measures current flow in the HV battery. This sensor locates between the positive contactor and the positive post of the HV battery. This sensor is similar to an amp clamp that can be used with a Digital Voltmeter (DVOM). The current sensor is an input to the BPCM and is used by the HCP. The BPCM uses the current sensor to verify pre-charge operation during battery connection. The signal is used by the BPCM to check for welded contactors when the battery is commanded to disconnect the HV system. The current sensor data can be read by the scan tool through the BPCM menu. This indicates current flow between the HV battery and the rest of the HV system. If the battery current is flowing to the TPIM and the rest of the HV system, the current displays as a positive reading. If the HV battery is being charged from the HV system, the current displays as a negative reading. Under typical operating conditions, the current level ranges up to 200 Amps of positive or negative current flow. If the current exceeds 250 Amps, the HCP reduces HV battery usage. The HCP uses the current signal in drivetrain management and checks for Loss of Isolation (LOI) testing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Service and Repair > High Voltage Battery - Removal Battery, Hybrid Drive: Service and Repair High Voltage Battery - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Service Precautions 1. Remove the rear seat See: Body and Frame/Seats/Service and Repair/Seat, Front/Seat Removal 2. Remove the terminal block cover assembly. 3. Remove the retainers from the strain relief clamp. 4. Remove the retainers from the wire terminals. 5. Remove push pins and remove the battery pack cooling duct (1). 6. Remove the battery pack vent tube (2) from the floor pan. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Service and Repair > High Voltage Battery - Removal > Page 2856 7. Disconnect the battery pack electrical connector (3). 8. Remove the battery pack mounting retainers. 9. Attach the battery lifting fixture 10182 to the battery back. 10. Remove the battery pack from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Service and Repair > High Voltage Battery - Removal > Page 2857 Battery, Hybrid Drive: Service and Repair High Voltage Battery - Installation INSTALLATION 1. Install the battery lifting adaptor 10182 on the battery pack. 2. Install the battery pack into the vehicle. 3. Install the battery pack mounting retainers. Tighten the two M8 retainers to 28 Nm (21 ft. lbs.). Tighten the six M12 retainers to 48 Nm (35 ft. lbs.). 4. Install the battery pack vent tube (2). 5. Install the battery pack cooling duct (1) and push pins. 6. Connect the battery pack electrical connector (3). 7. Install the nuts from the strain relief clamp. Tighten to 10 Nm (89 in. lbs.). 8. Install the nuts from the wire terminals. Tighten to 10 Nm (89 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery, Hybrid Drive > Component Information > Service and Repair > High Voltage Battery - Removal > Page 2858 9. Install the terminal block cover assembly. Tighten to 10 Nm (89 in. lbs.). 10. Install the rear seat See: Body and Frame/Seats/Service and Repair/Seat, Front/Seat Installation. 11. Perform the High Voltage Power Up procedure See: Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Condition Monitor, Hybrid Drive > Component Information > Description and Operation > Power Gauge - Description Battery Condition Monitor: Description and Operation Power Gauge - Description DESCRIPTION A power gauge is only found in the instrument clusters of vehicles equipped with the optional Hybrid Electrical Vehicle (HEV) system. The power gauge is located to the right side of the instrument cluster, just right of the speedometer. The power gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 200 degree scale on the gauge dial face that reads left-to-right on the outer circumference of the gauge scale CHARGING, ECONOMY and POWER. Text that reads HYBRIDappears within a gradated green wedge on the cluster overlay that extends above the hub of the power gauge needle toward the ECONOMY range of the scale. The power gauge graphics are white, blue, green and gray against a white field, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the white gauge dial face appears blue-green, the blue graphics still appear blue, the green graphics still appear green, the white text appears in blue-green silhouetted against a darkened blue, green or gray field and the red gauge needle still appears red. Gauge illumination is provided by an integral electro-luminescent lamp that is serviced as a unit with the instrument cluster. The power gauge is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Condition Monitor, Hybrid Drive > Component Information > Description and Operation > Power Gauge - Description > Page 2863 Battery Condition Monitor: Description and Operation Power Gauge - Operation OPERATION The power gauge gives an indication to the vehicle operator of how the Hybrid Electric Vehicle (HEV) is being operated in terms of the electric or gasoline modes and the relative gasoline fuel economy. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Hybrid Control Processor (HCP) integral to the Traction Power Inverter Module (TPIM) over the Controller Area Network (CAN) data bus. The power gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the far left end of the scale after the ignition switch turns to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Charging Position Message - Each time the cluster receives electronic messages from the HCP indicating that there is electrical energy being generated by the Regenerative Brake System (RBS) and that the high voltage battery of the HEV system is being recharged it positions the gauge needle within theCharging range of the gauge scale. The gauge needle remains within the Charging range until the cluster receives a message from the HCP to reposition the gauge needle, or until the ignition switch turns to the OFF position, whichever occurs first. Economy Position Message - Each time the cluster receives electronic messages from the HCP indicating that the vehicle is being operated in the fuel-saving hybrid electrical mode it positions the gauge needle to the appropriate relative position within the Hybrid and Economy ranges of the gauge scale. The closer the needle moves to the center of the Hybrid and Economy ranges indicates that the vehicle is achieving more fuel economy through reliance on the electrical mode of operation; while, the further the needle moves to the right of center indicates that the vehicle is achieving less fuel economy through additional reliance on the gasoline mode of operation. The gauge needle remains within the Hybrid and Economy ranges until the cluster receives a message from the HCP to reposition the gauge needle, or until the ignition switch turns to the OFF position, whichever occurs first. - Power Position Message - Each time the cluster receives electronic messages from the HCP indicating that the vehicle is achieving the least fuel economy through reliance entirely on the gasoline mode of operation it positions the gauge needle to the appropriate relative position within the Power range of the gauge scale. The further the needle moves toward the right end of the scale, the greater the power being demanded from the gasoline engine and the lower the fuel economy being achieved. The gauge needle remains within the Power range until the cluster receives a message from the HCP to reposition the gauge needle, or until the ignition switch turns to the OFF position, whichever occurs first. - Communication Error - If the cluster fails to receive a power gauge message, it holds the gauge needle at the last indication for about three seconds, or until the ignition switch turns to the OFF position, whichever occurs first. After three seconds, the gauge needle returns to the left end of the gauge scale. - Self Test - Each time the cluster is put through the self test, the power gauge needle is swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The HCP continually monitors the HEV system circuits, sensors and components as well as inputs from the Powertrain Control Module (PCM) to determine the appropriate HEV operating mode and power gauge positioning strategies. The HCP then sends the proper electronic messages to the instrument cluster, also known as the Cab Compartment Node (CCN) to control the power gauge needle position. For further diagnosis of the power gauge or the instrument cluster circuitry that controls the gauge, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the HEV systems, the HCP, the PCM, the CCN, the CAN data bus or the electronic communication related to power gauge operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Cooling Fan, Hybrid Drive > Battery Cooling Duct, Hybrid Drive > Component Information > Service and Repair > High Voltage Battery Vent Manifold Removal Battery Cooling Duct: Service and Repair High Voltage Battery Vent Manifold - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Remove the high voltage battery cover See: Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Removal. 2. Remove the fan shroud (1). 3. Remove the push pin (1), remove the air duct (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Cooling Fan, Hybrid Drive > Battery Cooling Duct, Hybrid Drive > Component Information > Service and Repair > High Voltage Battery Vent Manifold Removal > Page 2869 4. Remove the retainers from the panel assembly (1). 5. Disconnect the vent tube (2). 6. Remove the electrical connector from the bracket (3). 7. Disconnect the vent tube from the manifold (4). 8. Remove the vent tube from the panel assembly. 9. Remove the vent manifold (1). 10. Remove the battery vent tubes (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Cooling Fan, Hybrid Drive > Battery Cooling Duct, Hybrid Drive > Component Information > Service and Repair > High Voltage Battery Vent Manifold Removal > Page 2870 Battery Cooling Duct: Service and Repair High Voltage Battery Vent Manifold - Installation INSTALLATION 1. Install the battery vent tubes (2). 2. Install the vent manifold (1). 3. Install the vent tube in the panel assembly. 4. Install the retainers from the panel assembly (1). 5. Connect the vent tube to the manifold (4). 6. Install the electrical connector to the bracket (3). 7. Connect the vent tube (2). 8. Install the air duct (2), install the push pin (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Cooling Fan, Hybrid Drive > Battery Cooling Duct, Hybrid Drive > Component Information > Service and Repair > High Voltage Battery Vent Manifold Removal > Page 2871 9. Install the fan shroud (1). 10. Install the high voltage battery cover See: Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Installation. 11. Perform the high voltage power up procedure . See: Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Cooling Fan, Hybrid Drive > Battery Cooling Duct, Hybrid Drive > Component Information > Service and Repair > High Voltage Battery Vent Manifold Removal > Page 2872 Battery Cooling Duct: Service and Repair High Voltage Battery Vent Tube - Removal REMOVAL 1. Remove the passenger side high voltage battery trim panel. 2. Separate the vent hose at the junction (2). 3. Remove the vent hose from the floor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Cooling Fan, Hybrid Drive > Battery Cooling Duct, Hybrid Drive > Component Information > Service and Repair > High Voltage Battery Vent Manifold Removal > Page 2873 Battery Cooling Duct: Service and Repair High Voltage Battery Vent Tube - Installation INSTALLATION 1. Install the vent hose into the floor. 2. Connect the vent hose at the junction (2) . 3. Install the passenger side high voltage battery trim panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Cooling Fan, Hybrid Drive > Battery Cooling Fan Relay, Hybrid Drive > Component Information > Service and Repair > High Voltage Battery Cooling Fan Micro Relay - Removal Battery Cooling Fan Relay: Service and Repair High Voltage Battery Cooling Fan Micro Relay Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Remove the high voltage battery cover See: Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Removal. 2. Remove the eight bolts from the rear shield. 3. Remove the battery fan micro relay (1) at the rear of the battery pack (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Cooling Fan, Hybrid Drive > Battery Cooling Fan Relay, Hybrid Drive > Component Information > Service and Repair > High Voltage Battery Cooling Fan Micro Relay - Removal > Page 2878 Battery Cooling Fan Relay: Service and Repair High Voltage Battery Cooling Fan Micro Relay Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Install the micro relay. 2. Install the eight bolts for the rear shield. Tighten to 10 Nm (7 ft. lbs.). 3. Install the high voltage battery cover See: Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Installation. 4. Perform the high voltage power up procedure . See: Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Current Sensor, Hybrid Drive > Component Information > Service and Repair > High Voltage Current Sensor - Removal Battery Current Sensor: Service and Repair High Voltage Current Sensor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Service Precautions 1. Remove the high voltage battery cover See: Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Removal. 2. Remove the terminal block cover assembly. 3. Remove the four side shield bolts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Current Sensor, Hybrid Drive > Component Information > Service and Repair > High Voltage Current Sensor - Removal > Page 2883 4. Remove the two current sensor mounting bolts. 5. Remove the contactor terminal nut (1). 6. Slide the high voltage cable through the current sensor. 7. Install the HV Battery Cable Terminal Cover 10084 on the positive high voltage line. 8. Disconnect the connector from the bottom of the current sensor and remove. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Current Sensor, Hybrid Drive > Component Information > Service and Repair > High Voltage Current Sensor - Removal > Page 2884 Battery Current Sensor: Service and Repair High Voltage Current Sensor - Installation INSTALLATION 1. Connect the connector to the bottom of the current sensor. 2. Remove the HV Battery Cable Terminal Cover 10084 from the positive high voltage line. 3. Slide the high voltage cable through the current sensor. 4. Install the contactor terminal nut (1). Tighten to 3.4 Nm (30 in. lbs.) 5. Install the two current sensor mounting bolts. Tighten to 6 Nm (51 in. lbs.) 6. Install the four side shield bolts. Tighten to 6 Nm (51 in. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Current Sensor, Hybrid Drive > Component Information > Service and Repair > High Voltage Current Sensor - Removal > Page 2885 7. Install the high voltage battery cover See: Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Installation. 8. Perform the high voltage power up procedure . See: Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Hybrid Battery Bus / Cable > Battery Bus Junction Board, Hybrid Drive > Component Information > Service and Repair > High Voltage Terminal Block - Removal Battery Bus Junction Board: Service and Repair High Voltage Terminal Block - Removal REMOVAL WARNING: Before performing any diagnostic or service procedure, you must thoroughly read and follow all applicable High Voltage Safety Procedures. You must perform the High Voltage Power Down and Isolation Check. See: Service and Repair WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Remove the high voltage battery cover See: Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Removal. 2. Remove the retainers from the strain relief clamp. 3. Remove the retainers from the wire terminals. 4. Remove the nuts from the terminal cover assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Hybrid Battery Bus / Cable > Battery Bus Junction Board, Hybrid Drive > Component Information > Service and Repair > High Voltage Terminal Block - Removal > Page 2891 5. Disconnect the electrical connector (1) 6. Remove the screws (1) from the back of the terminal block. 7. Remove the three screws (3) that hold the lug terminal block (2) to the terminal panel assembly (1). 8. Remove the terminal block. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Hybrid Battery Bus / Cable > Battery Bus Junction Board, Hybrid Drive > Component Information > Service and Repair > High Voltage Terminal Block - Removal > Page 2892 Battery Bus Junction Board: Service and Repair High Voltage Terminal Block - Installation INSTALLATION 1. Install the three screws (3) that hold the lug terminal block (2) to the terminal panel assembly (1).Tighten to 6 Nm (51 in. lbs.). 2. Install the screws (1) from the back of the terminal block.Tighten to 6 Nm (53 in. lbs.). 3. Install the nuts to the terminal cover assembly. Tighten to 6 Nm (53 in. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Hybrid Battery Bus / Cable > Battery Bus Junction Board, Hybrid Drive > Component Information > Service and Repair > High Voltage Terminal Block - Removal > Page 2893 4. Connect the electrical connector (1). 5. Install the retainers from the strain relief clamp.Tighten to 10 Nm (7 ft. lbs.). 6. Install the retainers from the wire terminals.Tighten to 10 Nm (7 ft. lbs.). 7. Install the high voltage battery cover See: Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Hybrid Battery Cover > Component Information > Service and Repair > High Voltage Battery Cover - Removal Hybrid Battery Cover: Service and Repair High Voltage Battery Cover - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Remove the rear seat See: Body and Frame/Seats/Service and Repair/Seat, Front/Seat Removal. 2. Remove the terminal block cover assembly. 3. Remove the battery carpet. 4. Remove the screws and nuts from the top cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Hybrid Battery Cover > Component Information > Service and Repair > High Voltage Battery Cover - Removal > Page 2898 Hybrid Battery Cover: Service and Repair High Voltage Battery Cover - Installation INSTALLATION 1. Install the screws and nuts to the top cover. Tighten to 6 Nm (53 in. lbs.) 2. Install the terminal block cover assembly. Tighten to 10 Nm (7 ft. lbs.) 3. Install the high voltage battery carpet. 4. Install the rear seat See: Body and Frame/Seats/Service and Repair/Seat, Front/Seat - Removal 5. Perform the high voltage power up procedure . See: Service and Repair/Battery System - High Voltage Power Up 6. Install the high voltage battery trim covers (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Hybrid Battery Service Switch > Component Information > Service and Repair > High Voltage Service Disconnect - Removal Hybrid Battery Service Switch: Service and Repair High Voltage Service Disconnect - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Service Precautions 1. Remove the drivers side high voltage battery access panel. 2. Service disconnect (1) as it is active in the vehicle. 3. Pull up on the service disconnect handle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Hybrid Battery Service Switch > Component Information > Service and Repair > High Voltage Service Disconnect - Removal > Page 2903 4. Pull the handle down towards front of the vehicle. 5. Remove the service disconnect from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Hybrid Battery Service Switch > Component Information > Service and Repair > High Voltage Service Disconnect - Removal > Page 2904 Hybrid Battery Service Switch: Service and Repair High Voltage Service Disconnect - Installation INSTALLATION 1. Install the service disconnect into the vehicle. 2. Pull the handle up towards the roof of the vehicle. 3. Push down on the service disconnect handle. 4. Install the driver side high voltage battery cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Temperature Sensor/Switch, Hybrid Drive > Component Information > Service and Repair > High Voltage Thermistor Harness - Removal Battery Temperature Sensor/Switch: Service and Repair High Voltage Thermistor Harness Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Remove the battery cover See: Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Removal. 2. Remove the battery pack fan. See: Battery Cooling Fan/Service and Repair/High Voltage Battery Cooling Fan - Removal. 3. Mark the location of each thermistor. 4. Remove the push pins from the air intake thermistor. 5. Disconnect the current sensor (3) See: Battery Current Sensor/Service and Repair/High Voltage Current Sensor - Removal. 6. Disconnect the thermistor harness (1) from the Battery Pack Control Module (BPCM) (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Temperature Sensor/Switch, Hybrid Drive > Component Information > Service and Repair > High Voltage Thermistor Harness - Removal > Page 2909 7. Remove the thermistor harness (1) from the battery pack (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Temperature Sensor/Switch, Hybrid Drive > Component Information > Service and Repair > High Voltage Thermistor Harness - Removal > Page 2910 Battery Temperature Sensor/Switch: Service and Repair High Voltage Thermistor Harness Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Install the thermistor harness (1) into the marked locations. 2. Install the push pins for the air intake thermistor (1). 3. Install the battery pack fan See: Battery Cooling Fan/Service and Repair/High Voltage Battery Cooling Fan - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Battery System, Hybrid Drive > Battery Temperature Sensor/Switch, Hybrid Drive > Component Information > Service and Repair > High Voltage Thermistor Harness - Removal > Page 2911 4. Connect the current sensor (3) See: Battery Current Sensor/Service and Repair/High Voltage Current Sensor - Installation. 5. Connect the thermistor harness (1) to the Battery Pack Control Module (BPCM) (2). 6. Install the high voltage battery cover See: Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Installation. 7. Perform the High Voltage Power Up procedure . See: Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Drive Motor/Generator, Hybrid Drive > System Information > Locations Drive Motor/Generator: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Drive Motor/Generator, Hybrid Drive > System Information > Locations > Page 2915 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Drive Motor/Generator, Hybrid Drive > System Information > Diagrams > Transmission Assembly C1 (HEV) (Engine) 16 Way Drive Motor/Generator: Diagrams Transmission Assembly C1 (HEV) (Engine) 16 Way Connector C1 (HEV) - (ENGINE) 16 WAY ASSEMBLY-TRANSMISSION (HEV) - (ENGINE) 16 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Drive Motor/Generator, Hybrid Drive > System Information > Diagrams > Transmission Assembly C1 (HEV) (Engine) 16 Way > Page 2918 Drive Motor/Generator: Diagrams Transmission Assembly C2 (HEV) (Engine) 24 Way Connector C2 (HEV) - (ENGINE) 24 WAY ASSEMBLY-TRANSMISSION (HEV) - (ENGINE) 24 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Drive Motor/Generator, Hybrid Drive > System Information > Diagrams > Transmission Assembly C1 (HEV) (Engine) 16 Way > Page 2919 Drive Motor/Generator: Diagrams Transmission Assembly C3 (HEV) (Transmission) 6 Way Connector C3 (HEV) - (TRANSMISSION) 6 WAY ASSEMBLY-TRANSMISSION (HEV) - (TRANSMISSION) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Lamps and Indicators - Hybrid Drive System > Ready Lamp - Hybrid Drive > System Information > Description and Operation > Ready Indicator - Description Ready Lamp - Hybrid Drive: Description and Operation Ready Indicator - Description DESCRIPTION A Hybrid Electric Vehicle (HEV) ready indicator is only found in the instrument clusters of vehicles equipped with the optional hybrid system. This indicator is located in the center of the speedometer, in the area below and left of the speedometer needle hub. The HEV ready indicator consists of a stencil-like cutout of the text READY in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A green amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in green through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON the illumination intensity of the ready indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The HEV ready indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Lamps and Indicators - Hybrid Drive System > Ready Lamp - Hybrid Drive > System Information > Description and Operation > Ready Indicator - Description > Page 2925 Ready Lamp - Hybrid Drive: Description and Operation Ready Indicator - Operation OPERATION The Hybrid Electric Vehicle (HEV) ready indicator gives an indication to the vehicle operator when the Hybrid Control Processor (HCP) integral to the Traction Power Inverter Module (TPIM) has determined that the hybrid systems related circuits and components are prepared to move a vehicle that is stationary. The HEV ready indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the HCP over the Controller Area Network (CAN) data bus. The HEV ready indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the HEV ready indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the indicator illuminates for about four seconds as a bulb test. The entire bulb test is a function of the HCP. - HEV Ready Lamp-On Message - Each time the cluster receives an electronic HEV ready lamp-on message from the HCP indicating the HEV systems are in their ready state, the indicator illuminates. This reading indicates that the ignition switch is in the ON position, the vehicle is stationary (no vehicle speed input), the transmission gear selector lever is in any position and the HEV system is ready to move the vehicle. The indicator remains illuminated until the cluster receives a lamp-off message from the HCP, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the HEV ready indicator turns on during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The HCP continually monitors the HEV system circuits, sensors and components to decide whether the system is in good operating condition. The HCP also monitors a vehicle speed input to determine whether the vehicle is moving or stationary. The HCP then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the HEV ready indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the HEV system, the HCP, the CCN, the CAN data bus or the electronic communication related to HEV ready indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Lamps and Indicators - Hybrid Drive System > Malfunction Indicator Lamp - Hybrid Drive > Component Information > Description and Operation > Hybrid Service Indicator - Description Malfunction Indicator Lamp - Hybrid Drive: Description and Operation Hybrid Service Indicator Description DESCRIPTION A Hybrid Electric Vehicle (HEV) service indicator is only found in the instrument clusters of vehicles equipped with the optional hybrid system. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The HEV service indicator consists of a stencil-like cutout of the combined International Control and Display Symbol icon for Service, call for maintenance and a lightning bolt icon for Electricity in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The HEV service indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Lamps and Indicators - Hybrid Drive System > Malfunction Indicator Lamp - Hybrid Drive > Component Information > Description and Operation > Hybrid Service Indicator - Description > Page 2930 Malfunction Indicator Lamp - Hybrid Drive: Description and Operation Hybrid Service Indicator Operation OPERATION The Hybrid Electric Vehicle (HEV) service indicator gives an indication to the vehicle operator when the Hybrid Control Processor (HCP) integral to the Traction Power Inverter Module (TPIM) has recorded a Diagnostic Trouble Code (DTC) for a hybrid systems-related circuit or component malfunction. The HEV service indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the HCP over the Controller Area Network (CAN) data bus. The HEV service indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the HEV service indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the HCP. - HEV Service Lamp-On Message - Each time the cluster receives an electronic HEV service lamp-on message from the HCP, the indicator illuminates. For some DTCs, if a problem does not recur, the HCP sends a lamp-off message automatically. Other DTCs may require that a fault be repaired and the HCP be reset before a lamp-off message is sent. - Self Test - Each time the cluster is put through the self test, the HEV service indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The HCP continually monitors the HEV system circuits, sensors and components to decide whether the system is in good operating condition. The HCP then sends the proper lamp-on or lamp-off message to the instrument cluster also known as the Cab Compartment Node (CCN). For further diagnosis of the HEV service indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. If the CCN turns on the HEV service indicator after the bulb test, it may indicate that a malfunction has occurred and that the HEV system may require service. Use a diagnostic scan tool for proper diagnosis of the HEV system, the HCP, the CCN, the CAN data bus or the electronic communication related to HEV service indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Lamps and Indicators - Hybrid Drive System > Malfunction Indicator Lamp - Hybrid Drive > Component Information > Description and Operation > Hybrid Service Indicator - Description > Page 2931 Malfunction Indicator Lamp - Hybrid Drive: Description and Operation Regenerative Brake Indicator - Description DESCRIPTION A Regenerative Brake System (RBS) indicator is only found in the instrument clusters of vehicles equipped with the optional Hybrid Electrical Vehicle (HEV) system. This indicator is located below the minor gauge set on the left side of the cluster. The RBS indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Failure of Anti-lock Braking System in the opaque layer of the instrument cluster overlay, but with the letter R replacing the letter A in the ABS acronym. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The RBS indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Lamps and Indicators - Hybrid Drive System > Malfunction Indicator Lamp - Hybrid Drive > Component Information > Description and Operation > Hybrid Service Indicator - Description > Page 2932 Malfunction Indicator Lamp - Hybrid Drive: Description and Operation Regenerative Brake Indicator - Operation OPERATION The Regenerative Brake System (RBS) indicator gives an indication to the vehicle operator when the RBS system, or a circuit or component of the system is ineffective. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Regenerative Brake Controller (RBC) (also known as the Controller Antilock Brake/CAB) over the Controller Area Network (CAN) data bus. The RBS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the RBS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turns to the on position the RBS indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the RBC. - RBS Indicator Lamp-On Message - Each time the cluster receives an electronic RBS indicator lamp-on message from the RBC, the RBS indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the RBC, or until the ignition switch turns to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the RBC for five consecutive message cycles, the RBS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the RBC, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the instrument cluster is put through the self test, the RBS indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - RBS Diagnostic Test - The RBS indicator is blinked on and off by lamp-on and lamp-off messages from the RBC during the performance of the RBS diagnostic tests. The RBC continually monitors the RBS circuits and sensors to decide whether the system is in good operating condition. The RBC then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the RBC sends a lamp-on message after the bulb test, it indicates that the RBC has detected a system malfunction or that the RBS system has become ineffective. The RBC stores a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the RBS indicator fails to light due to an open or short in the cluster RBS indicator circuit, the cluster sends a message notifying the RBC of the condition, then the instrument cluster and the RBC will each store a DTC. Use a diagnostic scan tool for proper diagnosis of the regenerative brake system, the RBC, the CCN, the CAN data bus or the electronic communication related to RBS indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Drive Motor Power Relay > Component Information > Service and Repair > High Voltage Negative Contactor - Removal Drive Motor Power Relay: Service and Repair High Voltage Negative Contactor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Remove the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover Removal. 2. Remove the fan shroud (1). 3. Remove the push pin (1) and remove the air duct (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Drive Motor Power Relay > Component Information > Service and Repair > High Voltage Negative Contactor - Removal > Page 2938 4. Disconnect the fan electrical connector (1). 5. Disconnect the wire clip from the fan housing (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Drive Motor Power Relay > Component Information > Service and Repair > High Voltage Negative Contactor - Removal > Page 2939 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Drive Motor Power Relay > Component Information > Service and Repair > High Voltage Negative Contactor - Removal > Page 2940 Drive Motor Power Relay: Service and Repair High Voltage Negative Contactor - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Connect the negative contactor electrical connector, install the contactor. Tighten to 3.4 Nm (30 in. lbs.). 2. Remove the high voltage Battery Cable Terminal Cover 10084 from the cable. 3. Install the negative high voltage wires to the contactor. Tighten to 3.4 Nm (30 in. lbs.). 4. Install the fan. 5. Install the fan mounting bolts. Tighten the bolts to 6 Nm (53 in. lbs.) 6. Connect the fan electrical connector (1). 7. Connect the wire clip from the fan housing (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Drive Motor Power Relay > Component Information > Service and Repair > High Voltage Negative Contactor - Removal > Page 2941 8. Install the air duct (2) and the pushpin (1). 9. Install the fan shroud (1). 10. Install the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover Installation. 11. Perform the high voltage power up procedure . See: Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Drive Motor Power Relay > Component Information > Service and Repair > High Voltage Negative Contactor - Removal > Page 2942 Drive Motor Power Relay: Service and Repair High Voltage Positive Contactor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Remove the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover Removal. 2. Remove the current sensor See: Battery System, Hybrid Drive/Battery Current Sensor/Service and Repair/High Voltage Current Sensor - Removal. 3. Remove the contactor terminal nut (1). 4. Remove the harness from the harness clip. 5. Remove the three mounting nuts (1). 6. Disconnect the wire harnesses from the pre-charge relay and the positive contactor. 7. Remove the pre-contactor, pre-charge resistor and pre-charge relay assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Drive Motor Power Relay > Component Information > Service and Repair > High Voltage Negative Contactor - Removal > Page 2943 Drive Motor Power Relay: Service and Repair High Voltage Positive Contactor - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Install the pre-contactor, pre-charge resistor, and pre-charge relay assembly. 2. Install the three mounting nuts. Tighten to 6 Nm (53 in. lbs.) 3. Connect the wire harnesses to the pre-charge relay and the positive contactor. 4. Install the harness into the harness clip. 5. Install the contactor terminal nut (1). Tighten to 3.4 Nm (30 in. lbs.) 6. Install the current sensor See: Battery System, Hybrid Drive/Battery Current Sensor/Service and Repair/High Voltage Current Sensor - Installation . 7. Install the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Installation. 8. Perform the high voltage power up procedure . See: Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Hybrid Power Control Module > Component Information > Technical Service Bulletins > Customer Interest for Hybrid Power Control Module: > 08-002-10 > Jan > 10 > Hybrid Systems - MIL ON/Multiple DTC's Set Hybrid Power Control Module: Customer Interest Hybrid Systems - MIL ON/Multiple DTC's Set NUMBER: 08-002-10 GROUP: Electrical DATE: January 26, 2010 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P2096, P2097, P2098, P2099, P0420, P0430, P0606, P0776, P0752, P061B, P079B/A and POA8D. OVERVIEW: This bulletin involves flashing the Hybrid Control Processor (HCP), PCM module, Trans Control (TEHCM), and Accessory Power Module (APM) with new software. MODELS: 2009 HB Durango 2009 HG Aspen NOTE: This bulletin applies to HEV vehicles only (sales code EZE). SYMPTOM/CONDITION: Customers may experience an intermittent MIL Lamp with a code of P2096, P2097, P2098, and P2099, with no driveability complaints. Calibration update for the PCM will also address detonation knocking, and codes P0420 and P0430 that the customer may experience. For the TEHCM the software will eliminate the latching of P0606 caused by performing other flashes. It will prevent P0776 to set when P0752 is active. It will also improve diagnostics for the clutch 2 hydraulic system. For the HCP, the software change will reduce the possibility for P061B torque security to set before P079B/A Transmission Friction Element 2/1 Slip Detected code stored in the TEHCM, allowing for improved diagnostics. For the APM the software is for code POA8D APM system voltage low. This code may be found during a vehicle scan. It will not turn on the MIL and there will not be any driveability issues. DIAGNOSIS: If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the TEHCM with the latest software First followed by the PCM, HCP and APM modules using the wiTECH tool. Using the wiTECH Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Hybrid Power Control Module > Component Information > Technical Service Bulletins > Customer Interest for Hybrid Power Control Module: > 08-002-10 > Jan > 10 > Hybrid Systems - MIL ON/Multiple DTC's Set > Page 2952 Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP tab on upper portion of the wiTECH window, then "HELP CONTENTS. This will open the Welcome to wiTECH Help screen were help topics can now selected. After all modules are reprogrammed, the following must be performed: 2. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Hybrid Power Control Module > Component Information > Technical Service Bulletins > Customer Interest for Hybrid Power Control Module: > 08-034-08 > Nov > 08 > Hybrid Systems - DTC U0131 Diagnostics Hybrid Power Control Module: Customer Interest Hybrid Systems - DTC U0131 Diagnostics NUMBER: 08-034-08 GROUP: Electrical DATE: November 7, 2008 SUBJECT: Diagnosis Procedures For DTC U0131 OVERVIEW: This bulletin describes the different procedures required depending on whether DTC U0131 is an active or stored code. The MIL will NOT be illuminated. MODELS: 2009 (HB) Durango HEV 2009 (HG) Aspen HEV NOTE: This bulletin applies to vehicles equipped with a 5.7L Hybrid Engine (Sales Code EZE). SYMPTOM/CONDITION: The following DTC may be stored in the Hybrid Gateway Module (HGM). Further investigation by the technician may find that it is either stored or active: U0131 - Lost Communication With Power Steering Control Module (EPS). DISCUSSION: This DTC may set due to communication issues between different modules. If this code is active, then follow the related diagnosis procedures available in DealerCONNECT / TechCONNECT. If the DTC is stored, then clear the code and return the vehicle to the customer, no further action is required. The code has been set due to communication issues within the module and no repair is required. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Hybrid Power Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hybrid Power Control Module: > 08-002-10 > Jan > 10 > Hybrid Systems - MIL ON/Multiple DTC's Set Hybrid Power Control Module: All Technical Service Bulletins Hybrid Systems - MIL ON/Multiple DTC's Set NUMBER: 08-002-10 GROUP: Electrical DATE: January 26, 2010 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P2096, P2097, P2098, P2099, P0420, P0430, P0606, P0776, P0752, P061B, P079B/A and POA8D. OVERVIEW: This bulletin involves flashing the Hybrid Control Processor (HCP), PCM module, Trans Control (TEHCM), and Accessory Power Module (APM) with new software. MODELS: 2009 HB Durango 2009 HG Aspen NOTE: This bulletin applies to HEV vehicles only (sales code EZE). SYMPTOM/CONDITION: Customers may experience an intermittent MIL Lamp with a code of P2096, P2097, P2098, and P2099, with no driveability complaints. Calibration update for the PCM will also address detonation knocking, and codes P0420 and P0430 that the customer may experience. For the TEHCM the software will eliminate the latching of P0606 caused by performing other flashes. It will prevent P0776 to set when P0752 is active. It will also improve diagnostics for the clutch 2 hydraulic system. For the HCP, the software change will reduce the possibility for P061B torque security to set before P079B/A Transmission Friction Element 2/1 Slip Detected code stored in the TEHCM, allowing for improved diagnostics. For the APM the software is for code POA8D APM system voltage low. This code may be found during a vehicle scan. It will not turn on the MIL and there will not be any driveability issues. DIAGNOSIS: If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the TEHCM with the latest software First followed by the PCM, HCP and APM modules using the wiTECH tool. Using the wiTECH Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Hybrid Power Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hybrid Power Control Module: > 08-002-10 > Jan > 10 > Hybrid Systems - MIL ON/Multiple DTC's Set > Page 2962 Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP tab on upper portion of the wiTECH window, then "HELP CONTENTS. This will open the Welcome to wiTECH Help screen were help topics can now selected. After all modules are reprogrammed, the following must be performed: 2. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Hybrid Power Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hybrid Power Control Module: > 08-034-08 > Nov > 08 > Hybrid Systems - DTC U0131 Diagnostics Hybrid Power Control Module: All Technical Service Bulletins Hybrid Systems - DTC U0131 Diagnostics NUMBER: 08-034-08 GROUP: Electrical DATE: November 7, 2008 SUBJECT: Diagnosis Procedures For DTC U0131 OVERVIEW: This bulletin describes the different procedures required depending on whether DTC U0131 is an active or stored code. The MIL will NOT be illuminated. MODELS: 2009 (HB) Durango HEV 2009 (HG) Aspen HEV NOTE: This bulletin applies to vehicles equipped with a 5.7L Hybrid Engine (Sales Code EZE). SYMPTOM/CONDITION: The following DTC may be stored in the Hybrid Gateway Module (HGM). Further investigation by the technician may find that it is either stored or active: U0131 - Lost Communication With Power Steering Control Module (EPS). DISCUSSION: This DTC may set due to communication issues between different modules. If this code is active, then follow the related diagnosis procedures available in DealerCONNECT / TechCONNECT. If the DTC is stored, then clear the code and return the vehicle to the customer, no further action is required. The code has been set due to communication issues within the module and no repair is required. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Hybrid Power Control Module > Component Information > Technical Service Bulletins > Page 2967 Hybrid Power Control Module: Testing and Inspection TPIM - PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions Perform the following steps prior to any diagnostic procedure(s). 1. Check the Service Disconnect for proper installation. Some DTCs may set as a result of a removed or improperly installed Service Disconnect. 2. Only perform testing with the 12 volt battery fully charged to avoid false diagnosis. 3. Refer to applicable Technical Service Bulletins (TSBs) for controller software update information. Some conditions can be corrected by upgrading the Traction Power Inverter Module (TPIM) controller software. 4. Check for Service Information Tune-ups or Service Bulletins for any possible causes that may apply. 5. With the scan tool, perform the Vehicle Scan Report and record the results. 6. Read DTCs record the corresponding DTC Environmental Data. Use this data to identify the conditions in which the DTC was set. NOTE: Address active DTCs in the correct order. As a general rule, for any control module that exhibits more than one active DTC, address the codes in the order indicated: - Low/High Voltage and CAN Bus Loss of Communication Codes. - Module Internal Failure and Configuration Mismatch Codes. - Circuit specific DTC failures. 7. Refer to the When Monitored and Set Conditions for this DTC. DTCs can set at ignition on, at start up, driving under specific conditions, and after controller diagnostic monitors have run. 8. If the malfunction is still present after conducting this Pre-diagnostic Procedure, continue to the appropriate DTC procedure or symptom diagnostic. Did any of the above procedures repair the vehicle? Yes - Testing is complete. - Perform the TPIM VERIFICATION TEST . See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Traction Power Inverter Module (TPIM) Verification Test No - Perform the appropriate Hybrid Control Processor (HCP) diagnostic procedure(s). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Hybrid Power Control Module > Component Information > Service and Repair > Battery Pack Control Module - Removal Hybrid Power Control Module: Service and Repair Battery Pack Control Module - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions 1. Remove the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover Removal. 2. Remove the rear seat See: Body and Frame/Seats/Service and Repair/Seat, Front/Seat Removal. 3. Remove the current sensor See: Battery System, Hybrid Drive/Battery Current Sensor/Service and Repair/High Voltage Current Sensor - Removal. 4. Remove the positive contactor assembly See: Drive Motor Power Relay/Service and Repair/High Voltage Positive Contactor - Removal. 5. Remove and disconnect the battery pack control module. 6. Remove the battery pack control module mounting brackets. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Hybrid Power Control Module > Component Information > Service and Repair > Battery Pack Control Module - Removal > Page 2970 Hybrid Power Control Module: Service and Repair Battery Pack Control Module - Installation INSTALLATION 1. Install the battery pack control module mounting brackets on the battery pack control module. Tighten to 4.5 Nm (40 in. lbs.) 2. Install and connect the battery pack control module. 3. Install the positive contactor assembly See: Drive Motor Power Relay/Service and Repair/High Voltage Positive Contactor - Installation. 4. Install the current sensor See: Battery System, Hybrid Drive/Battery Current Sensor/Service and Repair/High Voltage Current Sensor - Installation . 5. Install the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover Installation. 6. Perform the high voltage power up procedure . See: Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Locations Voltage Inverter: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Locations > Page 2974 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Locations > Page 2975 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Locations > Page 2976 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Locations > Page 2977 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Diagrams > Traction Power Inverter Module C1 (HEV) (Engine) 56 Way Voltage Inverter: Diagrams Traction Power Inverter Module C1 (HEV) (Engine) 56 Way Connector C1 (HEV) - (ENGINE) 56 WAY MODULE-TRACTION POWER INVERTER (HEV) - (ENGINE) 56 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Diagrams > Traction Power Inverter Module C1 (HEV) (Engine) 56 Way > Page 2980 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Diagrams > Traction Power Inverter Module C1 (HEV) (Engine) 56 Way > Page 2981 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Diagrams > Traction Power Inverter Module C1 (HEV) (Engine) 56 Way > Page 2982 Voltage Inverter: Diagrams Traction Power Inverter Module C2 (HEV) (Engine) 8 Way Connector C2 (HEV) - (ENGINE) 8 WAY MODULE-TRACTION POWER INVERTER (HEV) - (ENGINE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Diagrams > Traction Power Inverter Module C1 (HEV) (Engine) 56 Way > Page 2983 Voltage Inverter: Diagrams Traction Power Inverter Module C3 (HEV) (Auxiliary Power Module) 1 Way Connector C3 (HEV) - (AUXILIARY POWER MODULE) 1 WAY MODULE-TRACTION POWER INVERTER (HEV) - (AUXILIARY POWER MODULE) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Diagrams > Traction Power Inverter Module C1 (HEV) (Engine) 56 Way > Page 2984 Voltage Inverter: Diagrams Traction Power Inverter Module C4 (HEV) (Auxiliary Power Module) 1 Way Connector C4 (HEV) - (AUXILIARY POWER MODULE) 1 WAY MODULE-TRACTION POWER INVERTER (HEV) - (AUXILIARY POWER MODULE) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Diagrams > Traction Power Inverter Module C1 (HEV) (Engine) 56 Way > Page 2985 Voltage Inverter: Diagrams Traction Power Inverter Module C1 (HEV) (Engine) 56 Way Connector C1 (HEV) - (ENGINE) 56 WAY MODULE-TRACTION POWER INVERTER (HEV) - (ENGINE) 56 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Diagrams > Traction Power Inverter Module C1 (HEV) (Engine) 56 Way > Page 2986 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Diagrams > Traction Power Inverter Module C1 (HEV) (Engine) 56 Way > Page 2987 Traction Power Inverter Module C2 (HEV) (Engine) 8 Way Connector C2 (HEV) - (ENGINE) 8 WAY MODULE-TRACTION POWER INVERTER (HEV) - (ENGINE) 8 WAY Traction Power Inverter Module C3 (HEV) (Auxiliary Power Module) 1 Way Connector C3 (HEV) - (AUXILIARY POWER MODULE) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Diagrams > Traction Power Inverter Module C1 (HEV) (Engine) 56 Way > Page 2988 MODULE-TRACTION POWER INVERTER (HEV) - (AUXILIARY POWER MODULE) 1 WAY Traction Power Inverter Module C4 (HEV) (Auxiliary Power Module) 1 Way Connector C4 (HEV) - (AUXILIARY POWER MODULE) 1 WAY MODULE-TRACTION POWER INVERTER (HEV) - (AUXILIARY POWER MODULE) 1 WAY Traction Power Inverter Module C5 (HEV) 2 Way Connector C5 (HEV) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Diagrams > Traction Power Inverter Module C1 (HEV) (Engine) 56 Way > Page 2989 MODULE-TRACTION POWER INVERTER (HEV) - 2 WAY Traction Power Inverter Module C6 (HEV) (Transmission) 3 Way Connector C6 (HEV) - (TRANSMISSION) 3 WAY MODULE-TRACTION POWER INVERTER (HEV) - (TRANSMISSION) 3 WAY Traction Power Inverter Module C7 (HEV) (Transmission) 3 Way Connector C7 (HEV) - (TRANSMISSION) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Diagrams > Traction Power Inverter Module C1 (HEV) (Engine) 56 Way > Page 2990 MODULE-TRACTION POWER INVERTER (HEV) - (TRANSMISSION) 3 WAY Traction Power Inverter Module C9 (HEV) (Engine) 1 Way Connector C9 (HEV) - (ENGINE) 1 WAY MODULE-TRACTION POWER INVERTER (HEV) - (ENGINE) 1 WAY Traction Power Inverter Module C10 (HEV) 2 Way Connector C10 (HEV) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Diagrams > Traction Power Inverter Module C1 (HEV) (Engine) 56 Way > Page 2991 MODULE-TRACTION POWER INVERTER (HEV) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Description and Operation > Traction Power Inverter Module - Description Voltage Inverter: Description and Operation Traction Power Inverter Module - Description DESCRIPTION The Traction Power Inverter Module (TPIM) (1) is located on the passenger side fender, under the hood. The large cover is the main body of the TPIM and the three phase connections are situated towards the center of the vehicle. The Auxiliary Power Module (APM) (9) is attached to the bottom of the TPIM. The TPIM (1) is one part in a modular part assembly that also contains the: - Auxiliary Power Module (APM) (9) - Two side brackets - Ground wires (10) - Terminal box cover (2) The TPIM has the following physical connections: - Two cooling tubes (7) - One Low Voltage (LV) 56-pin connector (LV power supply and sensor lines) (3) - One High Voltage (HV) power supply input connection for receiving HV from the HV battery pack (5) - One HV Direct Current (DC) output connection for supplying HV to the HV Electric Air Conditioning (EAC) compressor (6) - Two HV Alternating Current (AC) output connections (3-phase) to e-motor A and e-motor B - One connection for the two e-motor resolver sensor shield (clean ground) wires (one for e-motor A and one for e-motor B.) - The 8-pin connector (4) for the APM contains the network communication connections and the APM wake-up signal from the HGM - APM 12-Volt Output connection (8) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Description and Operation > Traction Power Inverter Module - Description > Page 2994 Voltage Inverter: Description and Operation Traction Power Inverter Module - Operation OPERATION TRACTION POWER INVERTER MODULE (TPIM) The Traction Power Inverter Module (TPIM) is descriptive of the function and operation. The TPIM consists of: - Traction = engineering term for electrical motor propulsion - Power = the TPIM provides the electrical power to the e-motors - Inverter = the TPIM is a DC to AC bi-directional inverter to provide AC current to and from the e-motors - Module = the TPIM contains the Hybrid Control Processor (HCP), which controls all drivetrain components and the Motor Control Processor (MCPa and MCPb), which directly control the motors ACCESSORY POWER MODULE (APM) The APM is often considered part of the TPIM assembly. The APM is physically attached to the bottom of the TPIM and services as one assembly with the TPIM. However, the two components are entirely separate components. The APM has three key tasks: - act as a bi-directional Direct Current (DC)/DC converter (300V/12V). - charge the 12V battery. - convert energy to the 12V system (no traditional generator used). The APM's maximum power output is 2200W and/or 175A. HYBRID CONTROL PROCESSOR (HCP) The HCP is the master of all modules involved in driving the HEV down the road. The HCP is located at the top of the TPIM, directly under the top cover. This cover should never be removed because the HCP is not serviceable separately from the rest of the TPIM assembly. The HCP acts as the controller and stores fault codes for the following modules: - Accessory Power Module (APM) - Battery Pack Control Module (BPCM) - Motor Control Processors (MCPa and MCPb) - Regenerative Braking System (RBS) Module - Transmission Auxiliary Oil Pump (TAOP) Controller All of the above modules are subordinates to the HCP and work under control of the HCP. The HCP takes inputs from all of these modules and processes them together to achieve optimum efficiency from the Hybrid drivetrain. The HCP connects, either directly or through network paths, to all of the modules, inputs, outputs sensors and actuators that affect hybrid propulsion and high voltage in the Durango/Aspen HEV. The HCP is connected to the Hybrid CAN bus for propulsion components and to the dedicated powertrain CAN for the communication to the PCM. A dedicated bus allows faster communication between the two most essential powertrain management modules, the HCP and the PCM. Either the HCP or the PCM can request illumination of the Malfunction Indicator Lamp (MIL). The HCP requests the MIL if any of the modules that the HCP controls indicate a failure that requires attention. The PCM requests the MIL if any engine related failures occur. The PCM contains the driver that activates the MIL. The ABS stores its own codes, and the HCP stores the same ABS codes. MOTOR CONTROL PROCESSORS (MCPa and MCPb) The MCPs function as slaves to the HCP. Under direction of the HCP, each MCP controls the speed, direction and output torque of the respective e-motor through the sequencing actuation of high current switching transistors. Each MCP controls a respective switching transistor that in-turn controls each e-motor. The e-motors operate using three-phase AC electricity. Three cables connect each e-motor to the TPIM. Each individually shielded cable is orange in color to alert technicians that the potential for high voltage is present. The HEV e-motors operate on three-phase AC. The TPIM controls the current to provide the requested speed and torque of each motor. The TPIM Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Description and Operation > Traction Power Inverter Module - Description > Page 2995 provides current to drive the motors so that: - AC flows through the three-phase windings in the stators - stators are energized in sequencing pairs around the motor - each stator coil experiences a magnetic field - a rotating magnetic field is created Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Service and Repair > Traction Power Inverter Module - Removal Voltage Inverter: Service and Repair Traction Power Inverter Module - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions NOTE: Do not remove the retainers from the Traction Power Inverter Module (TPIM) cover. 1. Remove the air cleaner housing (4).See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. 2. Disconnect the HVIL connector (1)(3) and remove the retainers holding the TPIM cover to the TPIM. Remove the TPIM cover (2). NOTE: Do not remove the retainers from the TPIM cover. 3. Remove the retainers (1) holding the high voltage cables (2) to the TPIM (3), then remove the high voltage cables (2) from the TPIM (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Service and Repair > Traction Power Inverter Module - Removal > Page 2998 4. Remove the high voltage cable at the TPIM from the A/C compressor (1) (2). 5. Remove the high voltage retainer (2) from the inside of the TPIM, then loosen the mounting retainers (1) from the high voltage battery. 6. Drain the cooling system. See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Draining. 7. Remove the TPIM coolant recovery container mounting bolt and position aside. 8. Disconnect the two TPIM coolant hoses (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Service and Repair > Traction Power Inverter Module - Removal > Page 2999 9. Disconnect the TPIM electrical connectors (2) and the resolver shield return wire to the TPIM (1). 10. Disconnect the TPIM ground wire. 11. Position the TPIM wire harness aside. 12. Remove the three mounting retainers on the front of the TPIM (1). 13. Remove the two mounting retainers on the back of the TPIM. 14. Remove the TPIM from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Service and Repair > Traction Power Inverter Module - Removal > Page 3000 15. If necessary, remove the six retainers and remove the TPIM mounting bracket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Service and Repair > Traction Power Inverter Module - Removal > Page 3001 Voltage Inverter: Service and Repair Traction Power Inverter Module - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions 1. Install the Traction Power Inverter Module (TPIM) mounting bracket into the vehicle. 2. Install the TPIM mounting bracket retainers. Tighten to 20 Nm (14.8 ft. lbs.). 3. Install the TPIM into the vehicle. 4. Install the two mounting retainers on the back of the TPIM. Tighten to 20 Nm (14.8 ft. lbs.). 5. Install the three mounting retainers on the front of the TPIM (1). Tighten to 20 Nm (14.8 ft. lbs.). 6. Position the TPIM wire harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Service and Repair > Traction Power Inverter Module - Removal > Page 3002 7. Connect the TPIM ground wire. 8. Connect the TPIM electrical connectors (2) and the resolver shield return wire to the TPIM (1). 9. Connect the two TPIM coolant hoses (1). 10. Position the TPIM coolant recovery container and install the mounting bolt. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Service and Repair > Traction Power Inverter Module - Removal > Page 3003 11. Install the high voltage cable at the TPIM from the A/C compressor (2). Tighten to 10 Nm (89 in.lbs.) 12. Install the high voltage cable at the Traction Power Inverter Module (TPIM) from the high voltage battery. Tighten to 10 Nm (89 in.lbs.). 13. Install the retainers (1) that hold the high voltage cables (2) to the TPIM (3). Tighten the exterior high voltage cables retainers (1) to the TPIM (3) to 10 Nm (89 in.lbs.). Tighten the retainers inside the TPIM (3) to 10 Nm (89 in.lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Power Control System, Hybrid Drive > Voltage Inverter, Hybrid Drive > Component Information > Service and Repair > Traction Power Inverter Module - Removal > Page 3004 14. Position the cover (2) to the TPIM and connect the HVIL connector (1)(3). Install the TPIM cover (2). Tighten to 10 Nm (89 in. lbs.) 15. Fill the cooling system . See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/TPIM Cooling System Filling 16. Perform high voltage system power up . See: Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Battery Cooling Fan Relay, Hybrid Drive > Component Information > Service and Repair > High Voltage Battery Cooling Fan Micro Relay - Removal Battery Cooling Fan Relay: Service and Repair High Voltage Battery Cooling Fan Micro Relay Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Remove the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover Removal. 2. Remove the eight bolts from the rear shield. 3. Remove the battery fan micro relay (1) at the rear of the battery pack (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Battery Cooling Fan Relay, Hybrid Drive > Component Information > Service and Repair > High Voltage Battery Cooling Fan Micro Relay - Removal > Page 3010 Battery Cooling Fan Relay: Service and Repair High Voltage Battery Cooling Fan Micro Relay Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Install the micro relay. 2. Install the eight bolts for the rear shield. Tighten to 10 Nm (7 ft. lbs.). 3. Install the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover Installation. 4. Perform the high voltage power up procedure . See: Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Hybrid Power Control Module > Component Information > Technical Service Bulletins > Customer Interest for Hybrid Power Control Module: > 08-002-10 > Jan > 10 > Hybrid Systems - MIL ON/Multiple DTC's Set Hybrid Power Control Module: Customer Interest Hybrid Systems - MIL ON/Multiple DTC's Set NUMBER: 08-002-10 GROUP: Electrical DATE: January 26, 2010 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P2096, P2097, P2098, P2099, P0420, P0430, P0606, P0776, P0752, P061B, P079B/A and POA8D. OVERVIEW: This bulletin involves flashing the Hybrid Control Processor (HCP), PCM module, Trans Control (TEHCM), and Accessory Power Module (APM) with new software. MODELS: 2009 HB Durango 2009 HG Aspen NOTE: This bulletin applies to HEV vehicles only (sales code EZE). SYMPTOM/CONDITION: Customers may experience an intermittent MIL Lamp with a code of P2096, P2097, P2098, and P2099, with no driveability complaints. Calibration update for the PCM will also address detonation knocking, and codes P0420 and P0430 that the customer may experience. For the TEHCM the software will eliminate the latching of P0606 caused by performing other flashes. It will prevent P0776 to set when P0752 is active. It will also improve diagnostics for the clutch 2 hydraulic system. For the HCP, the software change will reduce the possibility for P061B torque security to set before P079B/A Transmission Friction Element 2/1 Slip Detected code stored in the TEHCM, allowing for improved diagnostics. For the APM the software is for code POA8D APM system voltage low. This code may be found during a vehicle scan. It will not turn on the MIL and there will not be any driveability issues. DIAGNOSIS: If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the TEHCM with the latest software First followed by the PCM, HCP and APM modules using the wiTECH tool. Using the wiTECH Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Hybrid Power Control Module > Component Information > Technical Service Bulletins > Customer Interest for Hybrid Power Control Module: > 08-002-10 > Jan > 10 > Hybrid Systems - MIL ON/Multiple DTC's Set > Page 3019 Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP tab on upper portion of the wiTECH window, then "HELP CONTENTS. This will open the Welcome to wiTECH Help screen were help topics can now selected. After all modules are reprogrammed, the following must be performed: 2. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Hybrid Power Control Module > Component Information > Technical Service Bulletins > Customer Interest for Hybrid Power Control Module: > 08-034-08 > Nov > 08 > Hybrid Systems - DTC U0131 Diagnostics Hybrid Power Control Module: Customer Interest Hybrid Systems - DTC U0131 Diagnostics NUMBER: 08-034-08 GROUP: Electrical DATE: November 7, 2008 SUBJECT: Diagnosis Procedures For DTC U0131 OVERVIEW: This bulletin describes the different procedures required depending on whether DTC U0131 is an active or stored code. The MIL will NOT be illuminated. MODELS: 2009 (HB) Durango HEV 2009 (HG) Aspen HEV NOTE: This bulletin applies to vehicles equipped with a 5.7L Hybrid Engine (Sales Code EZE). SYMPTOM/CONDITION: The following DTC may be stored in the Hybrid Gateway Module (HGM). Further investigation by the technician may find that it is either stored or active: U0131 - Lost Communication With Power Steering Control Module (EPS). DISCUSSION: This DTC may set due to communication issues between different modules. If this code is active, then follow the related diagnosis procedures available in DealerCONNECT / TechCONNECT. If the DTC is stored, then clear the code and return the vehicle to the customer, no further action is required. The code has been set due to communication issues within the module and no repair is required. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Hybrid Power Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hybrid Power Control Module: > 08-002-10 > Jan > 10 > Hybrid Systems - MIL ON/Multiple DTC's Set Hybrid Power Control Module: All Technical Service Bulletins Hybrid Systems - MIL ON/Multiple DTC's Set NUMBER: 08-002-10 GROUP: Electrical DATE: January 26, 2010 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P2096, P2097, P2098, P2099, P0420, P0430, P0606, P0776, P0752, P061B, P079B/A and POA8D. OVERVIEW: This bulletin involves flashing the Hybrid Control Processor (HCP), PCM module, Trans Control (TEHCM), and Accessory Power Module (APM) with new software. MODELS: 2009 HB Durango 2009 HG Aspen NOTE: This bulletin applies to HEV vehicles only (sales code EZE). SYMPTOM/CONDITION: Customers may experience an intermittent MIL Lamp with a code of P2096, P2097, P2098, and P2099, with no driveability complaints. Calibration update for the PCM will also address detonation knocking, and codes P0420 and P0430 that the customer may experience. For the TEHCM the software will eliminate the latching of P0606 caused by performing other flashes. It will prevent P0776 to set when P0752 is active. It will also improve diagnostics for the clutch 2 hydraulic system. For the HCP, the software change will reduce the possibility for P061B torque security to set before P079B/A Transmission Friction Element 2/1 Slip Detected code stored in the TEHCM, allowing for improved diagnostics. For the APM the software is for code POA8D APM system voltage low. This code may be found during a vehicle scan. It will not turn on the MIL and there will not be any driveability issues. DIAGNOSIS: If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the TEHCM with the latest software First followed by the PCM, HCP and APM modules using the wiTECH tool. Using the wiTECH Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Hybrid Power Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hybrid Power Control Module: > 08-002-10 > Jan > 10 > Hybrid Systems - MIL ON/Multiple DTC's Set > Page 3029 Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP tab on upper portion of the wiTECH window, then "HELP CONTENTS. This will open the Welcome to wiTECH Help screen were help topics can now selected. After all modules are reprogrammed, the following must be performed: 2. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Hybrid Power Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hybrid Power Control Module: > 08-034-08 > Nov > 08 > Hybrid Systems - DTC U0131 Diagnostics Hybrid Power Control Module: All Technical Service Bulletins Hybrid Systems - DTC U0131 Diagnostics NUMBER: 08-034-08 GROUP: Electrical DATE: November 7, 2008 SUBJECT: Diagnosis Procedures For DTC U0131 OVERVIEW: This bulletin describes the different procedures required depending on whether DTC U0131 is an active or stored code. The MIL will NOT be illuminated. MODELS: 2009 (HB) Durango HEV 2009 (HG) Aspen HEV NOTE: This bulletin applies to vehicles equipped with a 5.7L Hybrid Engine (Sales Code EZE). SYMPTOM/CONDITION: The following DTC may be stored in the Hybrid Gateway Module (HGM). Further investigation by the technician may find that it is either stored or active: U0131 - Lost Communication With Power Steering Control Module (EPS). DISCUSSION: This DTC may set due to communication issues between different modules. If this code is active, then follow the related diagnosis procedures available in DealerCONNECT / TechCONNECT. If the DTC is stored, then clear the code and return the vehicle to the customer, no further action is required. The code has been set due to communication issues within the module and no repair is required. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Hybrid Power Control Module > Component Information > Technical Service Bulletins > Page 3034 Hybrid Power Control Module: Testing and Inspection TPIM - PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions Perform the following steps prior to any diagnostic procedure(s). 1. Check the Service Disconnect for proper installation. Some DTCs may set as a result of a removed or improperly installed Service Disconnect. 2. Only perform testing with the 12 volt battery fully charged to avoid false diagnosis. 3. Refer to applicable Technical Service Bulletins (TSBs) for controller software update information. Some conditions can be corrected by upgrading the Traction Power Inverter Module (TPIM) controller software. 4. Check for Service Information Tune-ups or Service Bulletins for any possible causes that may apply. 5. With the scan tool, perform the Vehicle Scan Report and record the results. 6. Read DTCs record the corresponding DTC Environmental Data. Use this data to identify the conditions in which the DTC was set. NOTE: Address active DTCs in the correct order. As a general rule, for any control module that exhibits more than one active DTC, address the codes in the order indicated: - Low/High Voltage and CAN Bus Loss of Communication Codes. - Module Internal Failure and Configuration Mismatch Codes. - Circuit specific DTC failures. 7. Refer to the When Monitored and Set Conditions for this DTC. DTCs can set at ignition on, at start up, driving under specific conditions, and after controller diagnostic monitors have run. 8. If the malfunction is still present after conducting this Pre-diagnostic Procedure, continue to the appropriate DTC procedure or symptom diagnostic. Did any of the above procedures repair the vehicle? Yes - Testing is complete. - Perform the TPIM VERIFICATION TEST . See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Traction Power Inverter Module (TPIM) Verification Test No - Perform the appropriate Hybrid Control Processor (HCP) diagnostic procedure(s). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Hybrid Power Control Module > Component Information > Service and Repair > Battery Pack Control Module - Removal Hybrid Power Control Module: Service and Repair Battery Pack Control Module - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions 1. Remove the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover Removal. 2. Remove the rear seat See: Body and Frame/Seats/Service and Repair/Seat, Front/Seat Removal. 3. Remove the current sensor See: Battery System, Hybrid Drive/Battery Current Sensor/Service and Repair/High Voltage Current Sensor - Removal. 4. Remove the positive contactor assembly See: Drive Motor Power Relay/Service and Repair/High Voltage Positive Contactor - Removal. 5. Remove and disconnect the battery pack control module. 6. Remove the battery pack control module mounting brackets. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Hybrid Power Control Module > Component Information > Service and Repair > Battery Pack Control Module - Removal > Page 3037 Hybrid Power Control Module: Service and Repair Battery Pack Control Module - Installation INSTALLATION 1. Install the battery pack control module mounting brackets on the battery pack control module. Tighten to 4.5 Nm (40 in. lbs.) 2. Install and connect the battery pack control module. 3. Install the positive contactor assembly See: Drive Motor Power Relay/Service and Repair/High Voltage Positive Contactor - Installation. 4. Install the current sensor See: Battery System, Hybrid Drive/Battery Current Sensor/Service and Repair/High Voltage Current Sensor - Installation . 5. Install the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover Installation. 6. Perform the high voltage power up procedure . See: Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Drive Motor Power Relay > Component Information > Service and Repair > High Voltage Negative Contactor - Removal Drive Motor Power Relay: Service and Repair High Voltage Negative Contactor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Remove the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover Removal. 2. Remove the fan shroud (1). 3. Remove the push pin (1) and remove the air duct (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Drive Motor Power Relay > Component Information > Service and Repair > High Voltage Negative Contactor - Removal > Page 3042 4. Disconnect the fan electrical connector (1). 5. Disconnect the wire clip from the fan housing (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Drive Motor Power Relay > Component Information > Service and Repair > High Voltage Negative Contactor - Removal > Page 3043 ERROR: undefined OFFENDING COMMAND: f‘~ STACK: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Drive Motor Power Relay > Component Information > Service and Repair > High Voltage Negative Contactor - Removal > Page 3044 Drive Motor Power Relay: Service and Repair High Voltage Negative Contactor - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Connect the negative contactor electrical connector, install the contactor. Tighten to 3.4 Nm (30 in. lbs.). 2. Remove the high voltage Battery Cable Terminal Cover 10084 from the cable. 3. Install the negative high voltage wires to the contactor. Tighten to 3.4 Nm (30 in. lbs.). 4. Install the fan. 5. Install the fan mounting bolts. Tighten the bolts to 6 Nm (53 in. lbs.) 6. Connect the fan electrical connector (1). 7. Connect the wire clip from the fan housing (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Drive Motor Power Relay > Component Information > Service and Repair > High Voltage Negative Contactor - Removal > Page 3045 8. Install the air duct (2) and the pushpin (1). 9. Install the fan shroud (1). 10. Install the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover Installation. 11. Perform the high voltage power up procedure . See: Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Drive Motor Power Relay > Component Information > Service and Repair > High Voltage Negative Contactor - Removal > Page 3046 Drive Motor Power Relay: Service and Repair High Voltage Positive Contactor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Remove the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover Removal. 2. Remove the current sensor See: Battery System, Hybrid Drive/Battery Current Sensor/Service and Repair/High Voltage Current Sensor - Removal. 3. Remove the contactor terminal nut (1). 4. Remove the harness from the harness clip. 5. Remove the three mounting nuts (1). 6. Disconnect the wire harnesses from the pre-charge relay and the positive contactor. 7. Remove the pre-contactor, pre-charge resistor and pre-charge relay assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Relays and Modules - Hybrid Drive > Drive Motor Power Relay > Component Information > Service and Repair > High Voltage Negative Contactor - Removal > Page 3047 Drive Motor Power Relay: Service and Repair High Voltage Positive Contactor - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Install the pre-contactor, pre-charge resistor, and pre-charge relay assembly. 2. Install the three mounting nuts. Tighten to 6 Nm (53 in. lbs.) 3. Connect the wire harnesses to the pre-charge relay and the positive contactor. 4. Install the harness into the harness clip. 5. Install the contactor terminal nut (1). Tighten to 3.4 Nm (30 in. lbs.) 6. Install the current sensor See: Battery System, Hybrid Drive/Battery Current Sensor/Service and Repair/High Voltage Current Sensor - Installation . 7. Install the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Installation. 8. Perform the high voltage power up procedure . See: Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Battery Current Sensor, Hybrid Drive > Component Information > Service and Repair > High Voltage Current Sensor - Removal Battery Current Sensor: Service and Repair High Voltage Current Sensor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions 1. Remove the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover Removal. 2. Remove the terminal block cover assembly. 3. Remove the four side shield bolts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Battery Current Sensor, Hybrid Drive > Component Information > Service and Repair > High Voltage Current Sensor - Removal > Page 3053 4. Remove the two current sensor mounting bolts. 5. Remove the contactor terminal nut (1). 6. Slide the high voltage cable through the current sensor. 7. Install the HV Battery Cable Terminal Cover 10084 on the positive high voltage line. 8. Disconnect the connector from the bottom of the current sensor and remove. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Battery Current Sensor, Hybrid Drive > Component Information > Service and Repair > High Voltage Current Sensor - Removal > Page 3054 Battery Current Sensor: Service and Repair High Voltage Current Sensor - Installation INSTALLATION 1. Connect the connector to the bottom of the current sensor. 2. Remove the HV Battery Cable Terminal Cover 10084 from the positive high voltage line. 3. Slide the high voltage cable through the current sensor. 4. Install the contactor terminal nut (1). Tighten to 3.4 Nm (30 in. lbs.) 5. Install the two current sensor mounting bolts. Tighten to 6 Nm (51 in. lbs.) 6. Install the four side shield bolts. Tighten to 6 Nm (51 in. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Battery Current Sensor, Hybrid Drive > Component Information > Service and Repair > High Voltage Current Sensor - Removal > Page 3055 7. Install the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover Installation. 8. Perform the high voltage power up procedure . See: Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Battery Temperature Sensor/Switch, Hybrid Drive > Component Information > Service and Repair > High Voltage Thermistor Harness - Removal Battery Temperature Sensor/Switch: Service and Repair High Voltage Thermistor Harness Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Remove the battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover - Removal. 2. Remove the battery pack fan. See: Battery System, Hybrid Drive/Battery Cooling Fan/Service and Repair/High Voltage Battery Cooling Fan Removal. 3. Mark the location of each thermistor. 4. Remove the push pins from the air intake thermistor. 5. Disconnect the current sensor (3) See: Battery Current Sensor/Service and Repair/High Voltage Current Sensor - Removal. 6. Disconnect the thermistor harness (1) from the Battery Pack Control Module (BPCM) (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Battery Temperature Sensor/Switch, Hybrid Drive > Component Information > Service and Repair > High Voltage Thermistor Harness - Removal > Page 3060 7. Remove the thermistor harness (1) from the battery pack (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Battery Temperature Sensor/Switch, Hybrid Drive > Component Information > Service and Repair > High Voltage Thermistor Harness - Removal > Page 3061 Battery Temperature Sensor/Switch: Service and Repair High Voltage Thermistor Harness Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions WARNING: Once the battery cover is removed from the battery, high voltage is still present in the system even with the service disconnect removed. When performing any diagnostic or service procedures, use extreme care with tools and other test equipment around unisolated terminals and wires. Failure to take proper precaution could result in serious or fatal injury. 1. Install the thermistor harness (1) into the marked locations. 2. Install the push pins for the air intake thermistor (1). 3. Install the battery pack fan See: Battery System, Hybrid Drive/Battery Cooling Fan/Service and Repair/High Voltage Battery Cooling Fan Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Battery Temperature Sensor/Switch, Hybrid Drive > Component Information > Service and Repair > High Voltage Thermistor Harness - Removal > Page 3062 4. Connect the current sensor (3) See: Battery Current Sensor/Service and Repair/High Voltage Current Sensor - Installation. 5. Connect the thermistor harness (1) to the Battery Pack Control Module (BPCM) (2). 6. Install the high voltage battery cover See: Battery System, Hybrid Drive/Hybrid Battery Cover/Service and Repair/High Voltage Battery Cover Installation. 7. Perform the High Voltage Power Up procedure . See: Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Hybrid Battery Service Switch > Component Information > Service and Repair > High Voltage Service Disconnect - Removal Hybrid Battery Service Switch: Service and Repair High Voltage Service Disconnect - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions 1. Remove the drivers side high voltage battery access panel. 2. Service disconnect (1) as it is active in the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Hybrid Battery Service Switch > Component Information > Service and Repair > High Voltage Service Disconnect - Removal > Page 3067 3. Pull up on the service disconnect handle. 4. Pull the handle down towards front of the vehicle. 5. Remove the service disconnect from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Hybrid Battery Service Switch > Component Information > Service and Repair > High Voltage Service Disconnect - Removal > Page 3068 Hybrid Battery Service Switch: Service and Repair High Voltage Service Disconnect - Installation INSTALLATION 1. Install the service disconnect into the vehicle. 2. Pull the handle up towards the roof of the vehicle. 3. Push down on the service disconnect handle. 4. Install the driver side high voltage battery cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Hybrid Drive Coolant Temperature Sensor > Component Information > Diagrams Hybrid Drive Coolant Temperature Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 2 WAY SENSOR-TPIM COOLANT TEMPERATURE (HEV) - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Hybrid Drive Coolant Temperature Sensor > Component Information > Diagrams > Page 3072 Hybrid Drive Coolant Temperature Sensor: Description and Operation TPIM COOLING SYSTEM TEMPERATURE SENSOR The TPIM cooling system temperature sensor (2) is used to sense the coolant temperature. The sensor (2) is located in the combination Transmission/TPIM cooler. The coolant sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. As the coolant temperature increases, resistance (voltage) in the sensor decreases. As the temperature decreases, resistance (voltage) in the sensor increases. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Hybrid Drive Coolant Temperature Sensor > Component Information > Service and Repair > TPIM Cooling System Temperature Sensor Removal Hybrid Drive Coolant Temperature Sensor: Service and Repair TPIM Cooling System Temperature Sensor - Removal TPIM COOLING SYSTEM TEMPERATURE SENSOR WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions 1. Perform HEV specific high voltage power down and high voltage isolation check safety procedures. See: Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the negative battery cable. CAUTION: Disconnecting the 12 V battery from the vehicle within two minutes of the last ignition key transition from Off to Run may cause a Battery Pack Control Module (BPCM) State Of Charge (SOC) mismatch. 3. Raise and support the vehicle. 4. Drain the TPIM cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/TPIM Cooling System Draining NOTE: DO NOT spill coolant on electrical connections or connectors. 5. Disconnect the temperature sensor electrical connector. 6. Remove the temperature sensor (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Hybrid Drive Systems > Sensors and Switches - Hybrid Drive > Hybrid Drive Coolant Temperature Sensor > Component Information > Service and Repair > TPIM Cooling System Temperature Sensor Removal > Page 3075 Hybrid Drive Coolant Temperature Sensor: Service and Repair TPIM Cooling System Temperature Sensor - Installation TPIM COOLING SYSTEM TEMPERATURE SENSOR WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Battery System, Hybrid Drive/Service Precautions 1. Install the temperature sensor (2) into the Transmission/TPIM cooler (1). 2. Tighten the sensor to 20 Nm (15 ft. lbs.). 3. Connect negative battery cable. 4. Perform HEV specific high voltage power up and high voltage isolation check safety procedures. See: Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 5. Fill the TPIM cooling system and check for leaks. See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/TPIM Cooling System Filling Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Front Control Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Front Control Module > Page 3083 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way Body Control Module: Diagrams Front Control Module (PDC AUX) 49 Way Connector - (PDC AUX) 49 WAY MODULE-FRONT CONTROL - (PDC AUX) 49 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 3086 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 3087 Body Control Module: Diagrams Front Control Module C1 (Headlamp And Dash) 24 Way Connector C1 - (HEADLAMP AND DASH) 24 WAY MODULE-FRONT CONTROL - (HEADLAMP AND DASH) 24 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 3088 Body Control Module: Diagrams Front Control Module C2 (Headlamp And Dash) 12 Way Connector C2 - (HEADLAMP AND DASH) 12 WAY MODULE-FRONT CONTROL - (HEADLAMP AND DASH) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 3089 Body Control Module: Diagrams Hybrid Gateway Module C1 (HEV) (Headlamp And Dash) 24 Way Connector C1 (HEV) - (HEADLAMP AND DASH) 24 WAY MODULE-HYBRID GATEWAY (HEV) - (HEADLAMP AND DASH) 24 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 3090 Body Control Module: Diagrams Hybrid Gateway Module C2 (HEV) (Headlamp And Dash) 12 Way Connector C2 (HEV) - (HEADLAMP AND DASH) 12 WAY MODULE-HYBRID GATEWAY (HEV) - (HEADLAMP AND DASH) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description Body Control Module: Description and Operation Gateway Module - Description DESCRIPTION Vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system have a Hybrid Gateway Module (HGM) (1) that is secured with three screws to the stamped steel Transmission Auxiliary Oil Pump (TAOP) control module mounting bracket located on the left hydro form (frame rail) near the back of the left front wheel housing within the engine compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum HGM housing is the electronic circuitry of the HGM, which includes a microprocessor and an electronic printed circuit board. A stamped metal cover plate (2) is sealed and secured to the HGM housing with four screws to enclose and protect the internal electronic circuitry and components. Two molded plastic electrical connectors (3), one containing 24 terminal pins and the other containing 12 terminal pins, exit the forward facing side of the HGM cover plate and are pointed downward. These terminal pins connect the HGM to the vehicle electrical system through two dedicated take outs and connectors of the headlamp and dash wire harness. The HGM housing has integral mounting flanges on two sides with three mounting holes in each flange. The mounting flange to the left of the connector receptacles is secured to the TAOP control module mounting bracket with two screws, while the flange on the right side is secured to the bracket with only one screw. The HGM cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description > Page 3093 Body Control Module: Description and Operation Front Control Module - Description DESCRIPTION The Front Control Module (FCM) is a micro controller based module located in the left front corner of the engine compartment. The front control module mates to the power distribution center to form the Integrated Power Module (IPM). The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The front control module controls power to some of these vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the CAN bus circuit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description > Page 3094 Body Control Module: Description and Operation Front Control Module - Operation OPERATION As messages are sent over the CAN bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are controlled by the FCM: - Front turn signals - Stop, turn signal and tail lamps - Front and rear hazard warning lamps - Headlamps - Fog Lamps - Daytime running lamps - if equipped - Horn - Windshield and liftgate wiper and washer systems - Transfer case shifting - Trailer tow wiring output - Rear window defroster power and timing - Air conditioning condenser cooling fan The FCM provides the following features for the above function: - It provides a illuminated approach feature that turns the headlamps on when the vehicle is unlocked with the Remote Keyless Entry (RKE) transmitter. - It flashes lamps in response to turn signal, RKE and Vehicle Theft Security System (VTSS) inputs. - It sounds the horn in response to RKE and VTSS inputs. - It turns off the horn in the event of excessively long operation that could otherwise damage the horn. - It turns off the windshield washer motor after 10 seconds of continuous operation to protect the motor. - It minimizes voltage variations to the headlamps to extend bulb life and to equalize the light output from the lamps, which might otherwise differ due to variations in wiring resistance. - If the headlamps are left on, it automatically turns them off after eight minutes to protect the battery from discharge.It monitors battery voltage and turns off non-essential functions such as the fog lamps, rear window defogger, and heated seats if necessary to conserve battery power. - It operates the high-beam headlamps at reduced intensity by pulse-width modulation of the power supply to provide the daytime running lamps. - It provides the variable delay intermittent windshield and liftgate wiper time delay features, and the vehicle speed sensitive windshield wiper delay variation. - It acts as a link between the CAN bus network for critical powertrain and anti-lock brake systems and the network for body and interior modules. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description > Page 3095 Body Control Module: Description and Operation Gateway Module - Operation OPERATION The Hybrid Gateway Module (HGM) provides a communication interface between the electronic control modules (nodes) in the vehicle, as well as with the diagnostic scan tool connected to the Controller Area Network (CAN) data bus system and the nodes connected to the Hybrid Local Area Network (H-LAN) data bus system. The HGM is the central gateway that processes and transfers messages between the different bus systems. In addition, the HGM is Local Interface Network (LIN) bus compatible. It receives a direct input over the LIN bus from a humidity sensor secured to the inside rear view mirror mount on the inside of the windshield glass, which it then transmits over the CAN data bus to other electronic modules in the vehicle. The microprocessor-based HGM also provides input and output circuitry that responds to both digital and analog inputs and provides electronically controlled higher current load outputs through lower current relay drivers. The HGM uses On-Board Diagnostics (OBD). If the HGM detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) that can be retrieved with a diagnostic scan tool through the 16-way data link connector located on the driver side lower edge of the instrument panel. The HGM connects directly to a fused battery current input and to ground, so that it remains capable of operating, regardless of the ignition switch position. The hardwired inputs and outputs for the HGM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the HGM, the electronic controls or communication between other modules and devices that provide features of the Hybrid Electric Vehicle (HEV) control system. The most reliable, efficient and accurate means to diagnose the HGM, the electronic controls and communication related to HGM operation, requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Front Control Module (FCM) Intermittent Condition Test Body Control Module: Testing and Inspection Front Control Module (FCM) Intermittent Condition Test INTERMITTENT CONDITION For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. INTERMITTENT CONDITION NOTE: The conditions that set the DTC are not present at this time. The following list may help in identifying the intermittent condition. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 1. Perform any Technical Service Bulletins (TSBs) that may apply. 2. Review the scan tool Freeze Frame information. If possible, try to duplicate the conditions under which the DTC set. 3. Turn the ignition off. 4. Visually inspect the related wire harness. Wiggle the related wire harness and look for an interrupted signal on the affected circuit. Disconnect all the related harness connectors. Look for any chafed, pierced, pinched, partially broken wires and broken, bent, pushed out, or corroded terminals. 5. Perform a voltage drop test on the related circuits between the suspected inoperative component and the Anti-Lock Brake Module, Front Control Module, or Totally Integrated Power Module, which every applies to the circuits in questions. 6. Inspect and clean all Powertrain Control Module (PCM), APS, engine, and chassis grounds that are related to the most current DTC. 7. If numerous trouble codes were set, use a wire schematic and look for any common ground or supply circuits 8. For any Relay DTCs, actuate the Relay with the scan tool and wiggle the related wire harness to try to interrupt the actuation. 9. Use the scan tool to perform a System Test if one applies to failing component. 10. A co-pilot, data recorder, and/or lab scope should be used to help diagnose intermittent conditions. Were any problems found during the above inspections? Yes - Perform the necessary repairs. - Perform the APS VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/APS Verification Test. No - Test Complete. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Front Control Module (FCM) Intermittent Condition Test > Page 3098 Body Control Module: Testing and Inspection Wireless Control Module (WCM) Intermittent Condition Test WIRELESS CONTROL MODULE (WCM) INTERMITTENT TEST For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. RECORD AND ERASE ALL WCM DIAGNOSTIC TROUBLE CODES (DTCS) Using a scan tool, record and erase all DTCs from the WCM. Monitor any active codes as you work through the following steps. - Review the code monitor and set conditions for any DTCs that are stored and attempt to reproduce the conditions listed. - Wiggle the wiring harness and connectors of the related circuit, sensor or component. - Turn the ignition off. Search for any Technical Service Bulletins (TSBs) that may apply. Was the source of the customer complaint found or did any DTCs appear and stay active? Yes - Make the appropriate repairs and perform the WIRELESS CONTROL MODULE (WCM) VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Wireless Control Module (WCM) Verification Test or select the correct DTC procedure. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. No - Go To 2 2. ATTEMPT TO REPRODUCE THE CONDITION In the event the customer complaint cannot be duplicated due to an intermittent condition in the theft/security system, the following may aid in attempting to reproduce the condition. - Using the wiring diagram/schematic as a guide, inspect the wiring and connectors related to the stored code or component in question. - Look for chafed, pierced, pinched, or partially broken wires and broken, bent, pushed out, spread, corroded, or contaminated terminals. - If the customer concern was related to a specific fobik, ensure the fobik in question is used while attempting reproduce the condition. - Reconnect any disconnected components and harness connectors and ensure they are properly seated. - If numerous trouble codes were set, use a schematic and inspect any common ground or supply circuits. Was the source of the intermittent condition located? Yes - Make the appropriate repairs and perform the WIRELESS CONTROL MODULE (WCM) VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Wireless Control Module (WCM) Verification Test No - The problem cannot be found at this time. If repeated intermittent failures are encountered that cannot be reproduced and the condition has prompted multiple customer visits to the dealership, document any findings on the repair order. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Front Control Module (FCM) Intermittent Condition Test > Page 3099 Body Control Module: Testing and Inspection Wireless Control Module (WCM) Pre-Diagnostic Procedure WIRELESS CONTROL MODULE (WCM) PRE-DIAGNOSTIC PROCEDURE Before attempting to repair any theft or security system, technicians should be familiar with and fully understand the system operation. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Description and Operation/Vehicle Theft Security System - Description. The following should be used as a checklist to be completed in its entirety prior to referencing specific Theft and Security Diagnostic Procedures. FOLLOW THE BASIC OUTLINE IN THE SIX-STEP TROUBLESHOOTING PROCEDURE - Verification of complaint - Verification of any related symptoms - Symptom analysis - Problem isolation - Repair of isolated problem - Verification of proper operation TAKE INTO ACCOUNT CURRENT VEHICLE CONDITION, REPAIR HISTORY, AND TECHNICAL SERVICE BULLETINS (TSBs) - Verify there are no outward signs of vehicle damage that could impact the proper operation of the theft or security system. Check for aftermarket vehicle accessories that may have been installed improperly or could interfere with the system - Check the vehicle repair history for repairs that may relate to the current condition. - Perform a check of current Technical Service Bulletins (TSB) for the system related to the customer concern. If a TSB applies, follow the procedure outlined in the TSB. DIAGNOSE ONLY THOSE FAILURES THAT ARE ACTIVE AND CAN BE REPRODUCED - Check the control module central to the subsystem that is exhibiting the condition for active Diagnostic Trouble Codes (DTCs). - For an intermittent failure that is not current at the time of vehicle inspection, refer to the WIRELESS CONTROL MODULE INTERMITTENT TEST See: Wireless Control Module (WCM) Intermittent Condition Test and document the event on the repair order. ADDRESS ACTIVE DTCS IN THE CORRECT ORDER - Low/High Voltage and Serial Data Loss of Communication Codes - Module Internal Failure and Configuration Mismatch Codes - Circuit specific DTC failures As a general rule, for any theft/security system control module that exhibits more than one active DTC, address the codes in the order indicated; should the malfunction still be present after conducting this Pre-diagnostic Procedure, technicians should continue to the appropriate DTC procedure or symptom diagnostic. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal Body Control Module: Service and Repair Gateway Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. A technician trained in proper Hybrid Electric Vehicle (HEV) service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. Unlatch and remove the Power Distribution Center (PDC) from the PDC mounting bracket on the left hydro form (frame rail) over the left front wheel house in the engine compartment. Move the PDC forward far enough to access the Hybrid Gateway Module (HGM) (1). 3. Remove the three screws (2) that secure the HGM to the Transmission Auxiliary Oil Pump (TAOP) control module mounting bracket (3) that is secured to the left hydro form near the back of the left front wheel house. 4. Disconnect the two headlamp and dash wire harness connectors (4) from the HGM connector receptacles located on the forward facing side of the module. 5. Remove the HGM from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal > Page 3102 Body Control Module: Service and Repair Gateway Module - Installation INSTALLATION 1. Position the Hybrid Gateway Module (HGM) (1) near the Transmission Auxiliary Oil Pump (TAOP) control module mounting bracket (3) that is secured to the left hydro form (frame rail) near the back of the left front wheel house in the engine compartment. 2. Reconnect the two headlamp and dash wire harness connectors (4) to the HGM connector receptacles located on the forward facing side of the module. 3. Position the HGM to the TAOP control module mounting bracket. 4. Install and tighten the three screws (2) that secure the HGM to the mounting bracket. Tighten the screws securely. 5. Reinstall the Power Distribution Center (PDC) onto the PDC mounting bracket on the left hydro form over the left front wheel house in the engine compartment. Be certain that each of the PDC latches is fully engaged with the mounting bracket. 6. Reconnect the battery negative cable. A technician trained in proper Hybrid Electric Vehicle (HEV) service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal > Page 3103 Body Control Module: Service and Repair Front Control Module - Removal REMOVAL 1. Disconnect the positive and negative battery cables from the battery. 2. Partially remove the Integrated Power Module (IPM) from the engine compartment. 3. Remove the front control module retaining screws. 4. Pull the front control module straight from the IPM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal > Page 3104 Body Control Module: Service and Repair Front Control Module - Installation INSTALLATION 1. Press the Front Control Module (FCM) onto the Integrated Power Module (IPM). 2. Install the mounting fasteners. 3. Install the IPM. 4. Connect the positive and negative battery cables. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3108 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way Engine Control Module: Diagrams Powertrain Control Module C1 38 Way Connector C1 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3111 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3112 Engine Control Module: Diagrams Powertrain Control Module C2 38 Way Connector C2 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3113 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3114 Engine Control Module: Diagrams Powertrain Control Module C3 38 Way Connector C3 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3115 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3116 Engine Control Module: Diagrams Powertrain Control Module C4 38 Way Connector C4 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3117 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description Engine Control Module: Description and Operation Powertrain Control Module - Description PCM POWERTRAIN CONTROL MODULE (PCM) The PCM (2) is attached to the right-front inner fender (1) located in the engine compartment. Modes of Operation MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3120 - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The O2S sensor heater element is energized via the ASD relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Starter motor relay - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the clutch relay. This is done if A/C has been selected by the vehicle operator and requested by the A/C thermostat. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3121 - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3122 If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5V Power Supplies 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Ignition Circuit Sense IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Powertrain Control Module (PCM). Battery voltage is supplied to the PCM through the ignition switch when the ignition is in the Run or Start position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Power Grounds POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Sensor Return SENSOR RETURN Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3123 The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. For more information, See: . Signal Ground SIGNAL GROUND Signal ground provides a low noise ground to the data link connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3124 Engine Control Module: Description and Operation Powertrain Control Module - Operation PCM POWERTRAIN CONTROL MODULE (PCM) The PCM is a pre-programmed, microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - Accelerator pedal position sensor (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CAN bus (+) circuits - CAN bus (-) circuits - Camshaft position sensor signal - Clutch Interlock Switch (if equipped) - Crankshaft position sensor - Data link connection for diagnostic scan tool - EGR position sensor (if equipped) - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensor(s) (if equipped) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure sensor - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission output speed sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3125 NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - CAN bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for diagnostic scan tool - Double start override (if equipped) - EGR valve control solenoid (if equipped) - Electronic throttle control - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle air control (IAC) motor - Ignition coil(s) - CAN bus circuits - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CAN bus circuits. - Overdrive indicator lamp (if equipped) - Radiator cooling fan (if equipped) - Speed control vacuum solenoid - Speed control vent solenoid - Starter relay - Tachometer (if equipped). Driven through CAN bus circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid 5V Power Supplies 5 VOLT SUPPLIES Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (if equipped with an RE automatic transmission). Ignition Circuit Sense IGNITION CIRCUIT SENSE The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3126 Engine Control Module: Testing and Inspection CHECKING THE PCM POWER AND GROUND CIRCUITS For a complete wiring diagram refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. PCM WIRING OR CONNECTORS 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and each connector at the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. No - Go To 2 2. CHECKING THE PCM GROUND CIRCUITS 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to 12 volts, check the PCM ground circuits. 3. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go To 3. No - Repair the PCM ground circuit(s) for an open circuit or high resistance. - Perform the POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3127 3. CHECKING THE PCM FUSED IGNITION CIRCUITS CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 1. Turn the ignition on. 2. Using a 12 volt test light connected to ground, check the PCM Fused Ignition circuits. 3. Check each circuit with the ignition on, engine running position, and during cranking. 4. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go To 4. No - Repair the open or short to ground in the PCM Fused Ignition circuits. - Perform the POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. 4. CHECKING THE PCM FUSED B+ CIRCUITS 1. Turn the ignition off. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3128 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to Ground, check the PCM Fused B+ circuits. 3. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright with the ignition on and not illuminated with the ignition off. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated as described above? Yes - Test complete. No - Repair the open or short to ground in the PCM Fused B+ circuit(s) for as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Resolver Learn STANDARD PROCEDURE - RESOLVER LEARN RESOLVER OFFSET LEARN TRIGGER EVT AHS-T TRANSMISSION The Resolver Offset Learn Trigger Procedure requires the use of a scan tool. This program allows the electronic variable transmission (EVT) AHS-T to re-calibrate itself. This will provide the proper transmission operation. The resolver offset learn procedure should be performed if any of the following procedures are performed: - Transmission Assembly Replacement - Transmission Electronic Hydraulic Control Module (TEHCM) Replacement - Flashing the TCM - Electric Motors Replacement - Valve Body Replacement or Recondition To perform the Resolver Offset Learn Trigger Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The shift lever position must stay in PARK until prompted to shift. - The calculated oil temperature must be above 15° C (60° F) and below 93° C (200° F) TCM Quick Learn QUICK LEARN TCM QUICK LEARN RFE and RLE The quick learn procedure requires the use of a scan tool. This program allows the electronic transmission system to re-calibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: - Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool indicates the procedure is complete - The calculated oil temperature must be above 15° C (60° F) and below 93° C (200° F) TCM Drive Learn DRIVE LEARN RFE and RLE When a transmission is repaired and a Quick Learn procedure has been performed on the Transmission Control Module (TCM), the following Drive Learn procedure can be performed to fine tune any shifts which are particularly objectionable. NOTE: It is not necessary to perform the complete Drive Learn procedure every time the TCM is Quick Learned. Perform only the portions which target the objectionable shift. LEARN A SMOOTH 1ST NEUTRAL TO DRIVE SHIFT Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3131 Perform this procedure only if the complaint is for a delayed or harsh shift the first time the transmission is put into gear after the vehicle is allowed to set with the engine not running for at least 10 minutes. Use the following steps to have the TCM learn the 1st N-D UD CVI. NOTE: The transmission oil temperature must be between 27-43° C (80-110° F). 1. Start the engine only when the engine and ignition have been off for at least ten (10) minutes. 2. With the vehicle at a stop and the service brake applied, record the 1st N-D UD CVI while performing a Neutral to Drive shift. The 1st N-D UD CVI accounts for air entrapment in the UD clutch that may occur after the engine has been off for a period of time. 3. Repeat 1 and 2 until the recorded 1st N-D UD CVI value stabilizes. NOTE: It is important that this procedure be performed when the transmission temperature is between 27-43° C (80-110° F). If this procedure takes too long to complete fully for the allowed transmission oil temperature, the vehicle may be returned to the customer with an explanation that the shift will improve daily during normal vehicle usage. The TCM also learns at higher oil temperatures, but these values (line pressure correction values) are not available for viewing on the scan tool. LEARN A SMOOTH NEUTRAL TO DRIVE GARAGE SHIFT Perform this procedure if the complaint is for a delayed or harsh shift when the transmission is put into gear after the vehicle has had its first shift. Use the following steps to have the TCM learn the Norm N-D UD CVI. NOTE: The transmission oil temperature must be between 27-43° C (80-110° F) to learn the UD CVI. Additional learning occurs at temperatures as low as -18° C (0° F) and as high as 93° C (200° F). This procedure may be performed at any temperature that experiences poor shift quality. Although the UD CVI may not change, shift quality should improve. 1. Start the vehicle engine and shift to drive. 2. Move the vehicle forward to a speed of at least 16 km/h (10 MPH) and come to a stop. This ensures no air is present in the UD hydraulic circuit. 3. Perform repeated N-D shifts at a stop while pausing in Neutral for at least 2-3 seconds and monitor Norm N-D UD CVI volume until the value stabilizes. The value will change during the N-D shift. This is normal since the UD value is different for the N-D shift then the normal value shown which is used for 4-3 coastdown and kick downs. Perform repeated shifts in this temperature range until the Norm N-D UD CVI value stabilizes and the N-D shifts become smooth. LEARN THE 1ST 2-3 SHIFT AFTER A RESTART OR SHIFT TO REVERSE Use the following steps to have the TCM learn the 1st 2-3 shift OD CVI. NOTE: The transmission oil temperature must be above 27° C (80° F). 1. With the vehicle engine running, select reverse gear for over 2 seconds. 2. Shift the transmission to Drive and accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform a 2-3 shift while noting the 1st 2-3 OD CVI. 3. Repeat 1 and 2 until the 1st 2-3 upshift becomes smooth and the 1st 2-3 OD CVI stabilizes. LEARN A SMOOTH 2-3 AND 3-4 UPSHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the OD and 4C CVI's. 1. Accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform multiple 1-2, 2-3, and 3-4 upshifts. The 2nd 2-3 shift following a restart or shift to reverse will be shown during the shift as a value between the 1st 2-3 OD CVI and the normal OD CVI. Updates to the normal OD CVI will occur after the 2nd shift into 3rd gear, following a restart or shift to reverse. 2. Repeat 1 until the 2-3 and 3-4 shifts become smooth and the OD and 4C CVI become stable. LEARN A SMOOTH 4-3 COASTDOWN AND PART THROTTLE 4-3 KICKDOWN NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the UD shift volume. 1. At a vehicle speed between 64-97 km/h (40-60 MPH), perform repeated 4-3 kickdown shifts. 2. Repeat 1 until the UD volume becomes somewhat stable and the shift becomes smooth. LEARN A SMOOTH 1-2 UPSHIFT AND 3-2 KICKDOWN Use the following steps to have the TCM learn the 2C shift volume. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3132 NOTE: The transmission oil temperature must be above 43° C (110° F). 1. With a vehicle speed below 48 km/h (30 MPH) and the transmission in 3rd gear, perform multiple 3-2 kick downs. 2. Repeat 1 until the 3-2 kick downs become smooth and the 2C CVI becomes stable. LEARN A SMOOTH MANUAL 2-1 PULLDOWN SHIFT AS WELL AS A NEUTRAL TO REVERSE SHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the LR volume. 1. With the vehicle speed around 40-48 km/h (25-30 MPH) in Manual 2nd, perform manual pulldowns to Low or 1st gear at closed throttle. 2. Repeat 1 until the LR CVI becomes stable and the manual 2-1 becomes smooth. LEARN A SMOOTH NEUTRAL TO REVERSE SHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). 1. With the vehicle at a stop, perform Neutral to Reverse shifts until the shift is smooth. An unlearned Neutral to Reverse shift may be harsh or exhibit a double bump. 2. If any of the shifts are still not smooth after the clutch volume stabilizes, an internal transmission problem may be present. LEARN A SMOOTH 4-5 UPSHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the Alt 2C CVI. 1. Accelerate the vehicle through 88 km/h (55 mph) at a steady 10-15 degree throttle opening and perform multiple 4-5 upshifts. 2. Repeat 1 until the 4-5 shift become smooth and the Alt 2C CVI become stable. There is a separate 2C volume used and learned for 4-5 shifts, 2CA. It is independent of the 2C CVI learned on 3-2 kick downs. PCM/ECM Reprogramming PCM/ECM REPROGRAMMING - GAS PCM / TCM FLASH REPROGRAMING This procedure will need to be done when one or more of the following situations are true: 1. A vehicle's Powertrain control module (PCM) has been replaced. 2. A diagnostic trouble code (DTC) is set "P1602 - PCM Not Programmed." 3. An updated calibration or software release is available for either the PCM or TCM ECUs. This procedure assumes that the StarSCAN(R) and StarMOBILE(R) devices are configured to your dealership's network with either a wired or wireless connection. The StarSCAN(R) and StarMOBILE(R) must also be running at the latest operating system and software release level. For more help on how to network your StarSCAN(R) or StarMOBILE(R) reference the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation' under the Download Center. Table of contents 1. SECTION 1 - PCM / TCM FLASH PROCEDURE SECTION 1 - PCM / TCM FLASH PROCEDURE 2. REQUIRED TOOLS/EQUIPMENT REQUIRED TOOLS/EQUIPMENT: 3. TECH TIPS and INFORMATIONTECH TIPS and INFORMATION: 4. PARTS REQUIRED PARTS REQUIRED SECTION 1 - PCM / TCM FLASH PROCEDURE If using StarSCAN(R) or StarMOBILE(R) Desktop Client. Go to REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client If using StarMOBILE(R) Stand-alone Diagnostic Mode. Go To REPAIR PROCEDURE - Using StarMOBILE(R) Stand-alone Diagnostic Mode REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3133 NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the StarSCAN(R) or StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power on the StarSCAN(R) or StarMOBILE(R). If the StarMOBILE(R) is being used, launch the StarMOBILE(R) Desktop Client and connect to the appropriate StarMOBILE(R) device. 4. Retrieve the old ECU part number. From the tool's Home screen, a. Select "ECU View" b. Select "PCM" c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the Flash PCM screen for later reference. 5. Program the ECU as follows: a. Using the StarSCAN(R) / StarMOBILE(R) at the Home screen, select "ECU View" b. Select "PCM" c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File" and follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 4e, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. g. Select "Download to Scantool" h. Once the download is complete, select "Close" and then "Back" i. Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. j. When the PCM update is complete, select "OK" k. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 6. Continue to SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 7. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See Section 3 SECTION 3 - AUTHORIZED MODIFICATION LABEL for details). REPAIR PROCEDURE - Using StarMOBILE(R) Stand-alone Diagnostic Mode NOTE: StarMOBILE(R) Stand-alone Mode is an efficient way to flash ECUs without having direct access to a network connection. It involves first copying the flash file to the StarMOBILE(R) device which DOES require a network connection. Once the file has been copied to the StarMOBILE(R) device, it can be used in a Stand-alone mode to flash the ECU WITHOUT a network connection. NOTE: StarMOBILE(R) does not need to be connected to a vehicle when retrieving a flash file for Stand-alone Mode. 1. Power on the StarMOBILE(R). Launch the StarMOBILE(R) Desktop Client and connect to the tool. 2. At the Home screen, select "ECU View" a. Select "PCM" b. Select "More Options" c. Select "ECU Flash" d. Select "Browse for New File" and follow the on screen instructions. e. Highlight the appropriate calibration based on the current ECU part number, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. 3. From the Flash File List, select the appropriate calibration for the PCM and select "Download to Client" 4. Once the download is complete, hit "OK" and then "Manage Files" Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3134 5. In the Manage Files screen, highlight the downloaded flash file and select "Copy to SM Device". A green check mark should now appear in the On SM Device column. 6. Exit the StarMOBILE(R) Desktop Client application. 7. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 8. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 9. On the StarMOBILE(R) device, select "Enter Stand-alone Diagnostic Mode" (use the right function key). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3135 NOTE: If a StarMOBILE(R) Desktop Client is still associated with the device, you will receive the following error: "Your StarMOBILE(R) device is currently locked by a pc named 'xxxxxxxx' on your network. To remove the lock, close its Desktop Client or reboot this device". 10. Program the ECU as follows: a. Select "ECU View" b. Select "PCM" c. Select "Flash ECU" d. Record the ECU part number at the very top of the screen for later reference. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3136 e. Highlight the flash file that you want to use. Hit "SELECT" and then "OK". Follow the on screen instructions. f. Once the flash is complete, verify that the part number at the top of the Flash PCM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 11. Continue to Section 2SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 12. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See Section 3 SECTION 3 - AUTHORIZED MODIFICATION LABEL for details). SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES Find the PCM/TCM Type for the vehicle, read and write down the steps, and then go to the step by step instructions for additional information on how to perform these procedures. STEP-BY-STEP INSTRUCTIONS If a NGC3 or NGC4 PCM was replaced, perform the following additional steps and/or routines: 1. PCM Replaced - if WCM equipped 2. Learn ETC - if ETC equipped 3. Check PCM Odometer 4. Check PCM VIN - if NOT WCM equipped 5. Quicklearn - if EATX equipped If a GPEC PCM was replaced, perform the following additional steps and/or routines: 1. If the vehicle is equipped with a CVT, ensure that the TCM has the latest software calibration available (if the vehicle is not equipped with a CVT, skip to Step 3). 2. PCM Replaced - if WCM equipped Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3137 3. Learn ETC 4. Check PCM Odometer 5. Check PCM VIN - if NOT WCM equipped 6. TCM Quicklearn - if EATX equipped If a CVT TCM was replaced, perform the following additional steps and/or routines: 1. Initialize CVT If an EGS TCM was replaced, perform the following additional steps and/or routines: 1. Initialize EGS STEP-BY-STEP INSTRUCTIONS Check PCM Odometer From the "Home" screen, select "ECU View". - Select "PCM" - Select "Misc. Functions" - Select "Check PCM Odometer" and follow the on screen instructions. - When complete, select "Finish". Check PCM VIN From the "Home" screen, select "ECU View" - Select "PCM" - Select "Misc. Functions" - Select "Check PCM VIN" and follow the on screen instructions. - When complete, select "Finish" Initialize CVT From the "Home" screen, select "ECU View" - Select "TCM" - Select "Misc. Functions" - Select "Initialize CVT" and follow the on screen instructions. - When complete, select "Finish" Initialize EGS From the "Home" screen, select "ECU View" - Select "TCM" - Select "Misc. Functions" - Select "Initialize EGS" and follow the on screen instructions. - When complete, select "Finish" Learn ETC From the "Home" screen, select "ECU View" - Select "PCM" - Select "Misc. Functions" - Select "Learn ETC" and follow the on screen instructions. - When complete, select "Finish" PCM Replaced The vehicle pin (Personal Identification Number) will be required to complete the routine. This information may be obtained in three ways: 1. The original selling invoice 2. Dealer CONNECT > Parts > Key Codes Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3138 3. Contacting the District Manager. From the "Home" screen, select "ECU View" - Select "WCM" - Select "Misc. Functions" - Select "PCM Replaced" and follow the on screen instructions. - When complete, select "Finish" Quicklearn From the "Home" screen, select "ECU View" - Select "PCM" - Select "Misc. Functions" - Select "Quicklearn" and follow the on screen instructions. - When complete, select "Finish" Update CVT TCM From the "Home" screen: - Select "ECU View" - Select "TCM" - Select "More Options" - Select "ECU Flash" - Select "Browse for New File" and follow the on screen instructions. - Highlight the appropriate calibration. - Select "Download to Scantool" - Once the download is complete, select "Close" and then "Back" - Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. - When the TCM update is complete, select "OK" - Verify that the part number at the top of the "Flash TCM" screen has updated to the latest level. SECTION 3 - AUTHORIZED MODIFICATION LABEL NOTE: The following step is required by law when reprogramming a PCM and/or TCM. Type the necessary information on the "Authorized Modification Label" and attach near the VECI label. 1. Powertrain Control / Transmission Control Module Part Numbers (Insert P/Ns) Used 2. Change Authority: TSB XX--XX 3. Dealer Code: XXXXX 4. Date: XX-XX-XX REQUIRED TOOLS/EQUIPMENT: TECH TIPS and INFORMATION: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3139 1. StarMOBILE(R) Stand-alone Diagnostic Mode is an efficient way to flash ECUs without having direct access to a network connection. It involves first copying the flash file to the StarMOBILE(R) device which DOES require a network connection. Once the file has been copied to the StarMOBILE(R) device, it can be used in a Stand-alone mode to flash the ECU WITHOUT a network connection. 2. To use the StarMOBILE(R) in Pass-Through Mode requires that your StarMOBILE(R) is connected to the dealerships network via a wired or wireless connection. For more information on how to use the StarMOBILE in Pass-Through Mode see the StarMOBILE(R) training tutorials available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Training Aids' link under the 'Training Aids' link. 3. StarMOBILE(R) does not need to be connected to a vehicle when retrieving a flash file for Stand-alone Mode. 4. Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The ECU can only be reprogrammed to a more recent version of that calibration. 5. If the flash process is interrupted or aborted, the flash should be restarted. 6. Due to the PCM / TCM programming procedure, a DTC may be set in other ECUs within the vehicle. Some DTCs may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 7. When replacing a GPEC PCM for a vehicle that is equipped with a CVT, it is extremely important that the PCM and TCM both have the latest software calibrations. 8. Do not allow the battery charger to time out or the charging rate to climb above 13.5 volts during the flash process. 9. The StarSCAN(R) and StarMOBILE(R) diagnostic tools fully support Internet connectivity and must be configured for your dealership's network. For help on setting up your StarSCAN(R) / StarMOBILE(R) for the dealership's network, refer to the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation' under the download center. 10. The operating software in the StarSCAN(R) and StarMOBILE(R) must be programmed with the latest software release level. The software level is visible in the blue header at the top of the StarSCAN(R) and StarMOBILE(R) Desktop Client screens. For instructions on how to update your scan tool, refer to the StarSCAN(R) / StarMOBILE(R) Software Update guide available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation' under the download center. PARTS REQUIRED SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3140 lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3141 - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3142 Engine Control Module: Removal and Replacement Powertrain Control Module - Removal REMOVAL CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. The PCM (2) is attached to the right-front inner fender (1) located in the engine compartment. To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect and isolate the negative battery cable. 2. Remove both wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal. 3. Remove wiper cowl (two screws, four pins). 4. Remove wiper cowl support (three bolts). 5. Remove air intake tube (four nuts). 6. Carefully unplug the four 38-way connectors (3) from PCM. 7. Remove three PCM mounting bolts (4), and remove PCM from vehicle. Powertrain Control Module - Installation INSTALLATION CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3143 1. Position PCM (2) to vehicle. 2. Install three PCM mounting bolts (4). 3. Tighten bolts to 3-5 Nm (30-40 in. lbs.). 4. Check pin connectors in the PCM. Also check the four 38-way connectors (3) for corrosion or damage. Repair as necessary. 5. Install the four 38-way connectors (3) to PCM. 6. Install air intake tube (four nuts). 7. Install wiper cowl support (three bolts). 8. Install wiper cowl (two screws, four pins). 9. Install both wiper arms. 10. Connect negative battery cable. 11. Use the diagnostic scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Auto Shut Down Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3147 Main Relay (Computer/Fuel System): Diagrams Connector (IN PDC) RELAY-AUTO SHUT DOWN (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay Description DESCRIPTION The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description > Page 3150 Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay - Operation PCM Output PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Removal REMOVAL The ASD relay is located in the engine compartment within the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal > Page 3153 Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Installation INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Fuel Pump Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay (In PDC) Fuel Pump Relay: Diagrams Fuel Pump Relay (In PDC) Connector (IN PDC) RELAY-FUEL PUMP (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay (In PDC) > Page 3160 Fuel Pump Relay: Diagrams Fuel Pump Speed Relay (HEV) (In PDC) Connector (HEV) - (IN PDC) RELAY-FUEL PUMP SPEED (HEV) - (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Description Fuel Pump Relay: Description and Operation Description DESCRIPTION The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the power distribution center cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Description > Page 3163 Fuel Pump Relay: Description and Operation Operation OPERATION The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shut-down the ground circuit to the fuel pump relay in approximately 1-3 seconds unless the engine is operating or the starter motor is engaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Service and Repair > Removal Fuel Pump Relay: Service and Repair Removal REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on power distribution center cover for relay location. 1. Remove power distribution center cover. 2. Remove relay from power distribution center. 3. Check condition of relay terminals and power distribution center connector terminals for damage or corrosion. Repair or replace as necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the power distribution center connector). Repair or replace as necessary before installing relay. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Service and Repair > Removal > Page 3166 Fuel Pump Relay: Service and Repair Installation INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on power distribution center cover for relay location. 1. Install relay to power distribution center. 2. Install cover to power distribution center. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Auto Shut Down Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3170 Main Relay (Computer/Fuel System): Diagrams Connector (IN PDC) RELAY-AUTO SHUT DOWN (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay Description DESCRIPTION The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description > Page 3173 Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay - Operation PCM Output PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Removal REMOVAL The ASD relay is located in the engine compartment within the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal > Page 3176 Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Installation INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3182 Accelerator Pedal Position Sensor: Diagrams Connector - (HEADLAMP AND DASH) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (HEADLAMP AND DASH) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (6) is attached to the accelerator pedal assembly (4) under the instrument panel. The APPS is used only with the 5.7L V-8 engine. The APPS is part of the pedal assembly and is a non-serviceable part and the pedal assembly has to be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 3185 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) is a linear potentiometer. It provides the Powertrain Control Module (PCM) with a DC voltage signal proportional to the angle, or position of the accelerator pedal. The APPS signal is translated (along with other sensors) to place the throttle plate (within the throttle body) to a pre-determined position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor > Page 3190 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3191 Camshaft Position Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-CAMSHAFT POSITION - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description 5.7L The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 3194 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation 5.7L The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.7L The Camshaft Position Sensor (CMP) (3) is located on right side of timing gear/chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from timing gear/chain cover. 4. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 3197 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in timing gear/chain cover. 2. Install sensor (2) into timing gear/chain cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing gear/chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 Nm (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3201 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3202 Coolant Temperature Sensor/Switch (For Computer): Diagrams Connector - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3206 Crankshaft Position Sensor: Diagrams Connector (5.7L) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (5.7L) - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description 5.7L The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 3209 Crankshaft Position Sensor: Description and Operation Operation 5.7L Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On the 5.7L V-8 engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 5.7L 1. Raise vehicle. 2. Disconnect CKP electrical connector (2) at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 3212 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking and twisting action. CAUTION: Before tightening the CKP sensor mounting bolt, be sure the sensor is completely flush to the cylinder block. If the CKP sensor is not flush, damage to the sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3216 Fuel Level Sensor: Diagrams Connector - (CHASSIS) 4 WAY MODULE-FUEL PUMP - (CHASSIS) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Level Sensor: Description and Operation Fuel Pump Module - Description DESCRIPTION The fuel pump module assembly (4) is located on the top of the fuel tank (2). The module assembly (5) contains the following components: - An internal fuel filter - A separate fuel pick-up, or inlet filter (3) - A fuel pressure regulator (4) - An electric fuel pump (2) - A lock ring to retain pump module to tank - A soft gasket between tank flange and module - A fuel gauge sending unit (fuel level sensor) (1) - Fuel line connection (6) If the fuel gauge sending unit, electrical fuel pump, primary inlet filter, fuel filter or fuel pressure regulator require service, the fuel pump module must be replaced. Electric Fuel Pump The electric fuel pump is located inside of the fuel pump module. A 12 volt, permanent magnet, electric motor powers the fuel pump. The electric fuel pump is not a separate, serviceable component. Fuel Filters Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3219 Two fuel filters are used. One is located at the bottom of the fuel pump module. The other is located inside the module. A separate frame mounted fuel filter is not used with any engine. Both fuel filters are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator The fuel pressure regulator is located within fuel pump module. Fuel Gauge Sending Unit (Fuel level sensor) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3220 Fuel Level Sensor: Description and Operation Variable Speed Fuel Pump Module (HEV) Description DESCRIPTION - HEV The variable speed fuel pump module (5) is located on the top of the fuel tank and contains the following: - Internal fuel filter - Separate fuel pick-up, or inlet filter (3) - Fuel pressure regulator (4) - Variable speed fuel pump (2) - Lock ring to retain the pump module to the tank - O-ring gasket between the tank flange and pump module - Fuel gauge sending unit (fuel level sensor) (1) - Fuel line connection (6) If the fuel gauge sending unit (fuel level sensor), variable speed fuel pump, primary inlet filter, fuel filter or fuel pressure regulator require service, the variable speed fuel pump module must be replaced as a unit. Variable Speed Fuel Pump The Hybrid Electric Vehicle (HEV) uses a variable speed fuel pump module, an additional fuel pump speed relay and a resistor to provide low speed capability to the fuel pump system. A diagnostic monitor circuit allows the PCM to verify operation of the following two circuits: - Fuel pump relay control circuit which results in closing the fuel pump relay allowing current to flow through the fuel pump speed relay for high speed fuel pump operation. - Fuel pump speed relay control circuit which results in closing the fuel pump relay and fuel pump speed relay allowing current to flow through the resistor for low speed fuel pump operation. The variable speed fuel pump is not a separate, serviceable component. Fuel Filters Two fuel filters are used. One is located at the bottom of the fuel pump module. The other is located inside the module. A separate frame mounted fuel filter is not used. Both fuel filters are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator The fuel pressure regulator is located within the fuel pump module and is not a separate, serviceable component. Fuel Gauge Sending Unit (fuel level sensor) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, a float arm, and a variable resistor track (card). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Level Sensor: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: The fuel system is under a constant pressure, even with the engine off. Before servicing the fuel pump module, the fuel system pressure must be released. 1. Perform the fuel system pressure release procedure See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect and isolate the negative battery cable. 3. Drain and remove the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank Removal 4. Note the rotational position of the module before attempting removal. An indexing arrow is located on top of the module for this purpose. 5. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 6. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 7. Rotate the breaker bar counterclockwise to remove the lock ring. 8. Remove the lock ring. The module will spring up slightly when the lock ring is removed. 9. Remove the module from the fuel tank. Be careful not to bend the float arm during removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3223 Fuel Level Sensor: Service and Repair Fuel Pump Module - Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position the fuel pump module into the opening of the fuel tank. 2. Rotate the module until the embossed alignment arrow points to the center alignment mark. This step must be performed to prevent the float from contacting the side of the fuel tank. Also be sure the fuel fitting on top of the pump module is pointed to the left side of the vehicle. 3. Position the lock ring (5) over the top of the fuel pump module. 4. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 5. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 6. Tighten the lock ring (clockwise) until all seven notches have engaged. 7. Install the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation 8. Lower the vehicle. 9. Connect the fuel line quick connect fitting to the fuel rail (1)See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair 10. Connect the negative battery cable. 11. Install the fuel fill cap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3224 Fuel Level Sensor: Service and Repair Variable Speed Fuel Pump Module (HEV) - Removal REMOVAL - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: The fuel system is under a constant pressure, even with the engine off. Before servicing the fuel pump module, the fuel system pressure must be released. 1. Perform the fuel system pressure release procedure See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 3. Disconnect the 12 volt battery system ground isolation connector (1). 4. Drain the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Procedures for Draining Fuel Tank HEV procedure. 5. Remove the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal NOTE: Prior to removing the variable speed fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. CAUTION: An indexing arrow is located on top of the variable speed fuel pump module to clock it's position into the fuel tank, note it's location for reassembly. 6. Position the lock ring remover/installer 9340 (1) into the notches on the outside edge of the lock ring (2). 7. Install a 1/2 inch drive breaker bar (4) into the lock ring remover/installer 9340 (1). NOTE: The variable speed fuel pump module will spring up slightly when the lock ring is removed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3225 8. Rotate the breaker bar counterclockwise and remove the lock ring. CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 9. Remove the variable speed fuel pump module (3) from the fuel tank. Be careful not to bend the float arm during removal. 10. Remove and discard the rubber O-ring seal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3226 Fuel Level Sensor: Service and Repair Variable Speed Fuel Pump Module (HEV) - Installation INSTALLATION - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Using a new rubber O-ring seal, position the variable speed fuel pump module into the opening of the fuel tank. 2. Rotate the variable speed fuel pump module until the embossed alignment arrow points to the center alignment mark as noted during disassembly. This step must be performed to prevent the float from contacting the side of the fuel tank. 3. Position the lock ring (2) over the top of the variable speed fuel pump module (3). 4. Position the lock ring remover/installer 9340 (1) into the notches on the outside edge of the lock ring (2). 5. Install a 1/2 inch drive breaker bar (4) into the lock ring remover/installer 9340 (1). 6. Tighten the lock ring (clockwise) until all seven notches have engaged. 7. Install the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank Installation 8. Lower the vehicle. 9. Install the fuel fill cap. 10. Connect the fuel line quick connect fitting to the fuel rail (1)See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3227 11. Connect the 12 volt battery system ground isolation connector (1). 12. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 13. Start the engine and check for leaks at all fuel tank connections. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Pressure Sensor: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set Fuel Tank Pressure Sensor: Customer Interest Fuel System - MIL ON/DTC P1446 Set NUMBER: 08-005-10 GROUP: Electrical DATE: April 01, 2010 SUBJECT: Fuel Tank Pressure Sensor Connector OVERVIEW: This Bulletin involves replacing the fuel tank pressure sensor connector for diagnostic Trouble Code (DTC) P1446 - Fuel Tank Control System Performance - HEV. MODELS: 2009 (HB) Durango 2009 (HG) Aspen SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that DTC P1446 - Fuel Tank Control System Performance - HEV has been set. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN) verify if P1446 - Fuel Tank Control System Performance - HEV is active. If DTC P1446 - Fuel Tank Control System Performance - HEV is active proceed with repair. Check the service history of the vehicle. If the DTC has ever been reported in the past then proceed with the repair. If DTC's are present other then the one listed above record them on the repair order and with the appropriate Diagnostic Procedures available in TechCONNECT repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: 1. Lower the fuel tank as per the directions on tech connect Emissions Control > Evaporative Emissions > Sensor, Fuel Pressure HEV > Removal HEV. 2. Remove convoluted tubing from the wiring harness. 3. Cut the wires going to the sensor connector 2 inches from the connector. 4. Using the standard crimp/solder/heat shrink procedure for wire splicing found in DealerCONNECT > TechCONNECT > Wiring > Wiring Diagram Information > Wire, add new harness extension to vehicle harness. 5. Check the Pressure Sensor for corrosion on the sensor it self, is it corroded? a. No >>> proceed to Step # 6. b. Yes >>> replace the sensor and continue with repairs. 6. Reinstall connector on to the sensor. 7. Wrap convolute with electrical tape. 8. Reinstall Fuel tank into the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Pressure Sensor: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set > Page 3236 9. Perform StarSCAN diagnostics, clear any stored codes. Re-key to confirm P1446 fault is not active. 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set Fuel Tank Pressure Sensor: All Technical Service Bulletins Fuel System - MIL ON/DTC P1446 Set NUMBER: 08-005-10 GROUP: Electrical DATE: April 01, 2010 SUBJECT: Fuel Tank Pressure Sensor Connector OVERVIEW: This Bulletin involves replacing the fuel tank pressure sensor connector for diagnostic Trouble Code (DTC) P1446 - Fuel Tank Control System Performance - HEV. MODELS: 2009 (HB) Durango 2009 (HG) Aspen SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that DTC P1446 - Fuel Tank Control System Performance - HEV has been set. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN) verify if P1446 - Fuel Tank Control System Performance - HEV is active. If DTC P1446 - Fuel Tank Control System Performance - HEV is active proceed with repair. Check the service history of the vehicle. If the DTC has ever been reported in the past then proceed with the repair. If DTC's are present other then the one listed above record them on the repair order and with the appropriate Diagnostic Procedures available in TechCONNECT repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: 1. Lower the fuel tank as per the directions on tech connect Emissions Control > Evaporative Emissions > Sensor, Fuel Pressure HEV > Removal HEV. 2. Remove convoluted tubing from the wiring harness. 3. Cut the wires going to the sensor connector 2 inches from the connector. 4. Using the standard crimp/solder/heat shrink procedure for wire splicing found in DealerCONNECT > TechCONNECT > Wiring > Wiring Diagram Information > Wire, add new harness extension to vehicle harness. 5. Check the Pressure Sensor for corrosion on the sensor it self, is it corroded? a. No >>> proceed to Step # 6. b. Yes >>> replace the sensor and continue with repairs. 6. Reinstall connector on to the sensor. 7. Wrap convolute with electrical tape. 8. Reinstall Fuel tank into the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set > Page 3242 9. Perform StarSCAN diagnostics, clear any stored codes. Re-key to confirm P1446 fault is not active. 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3246 Intake Air Temperature Sensor: Diagrams Connector HEV - (ENGINE) 2 WAY SENSOR-INTAKE AIR TEMPERATURE HEV - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor - Description Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Description DESCRIPTION The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor - Description > Page 3249 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Operation OPERATION The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal 5.7L The intake manifold air temperature (IAT) sensor is installed into the front of the intake manifold air box plenum (1). 1. Disconnect electrical connector (2) from IAT sensor. 2. Clean dirt from intake manifold at sensor base. 3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counterclockwise for removal. 4. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 3252 Intake Air Temperature Sensor: Service and Repair Installation 5.7L 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold (1). 3. Position sensor (2) into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) Knock Sensor: Locations Knock Sensor 1 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3257 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3258 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3259 Knock Sensor: Locations Knock Sensor 2 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3260 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way Knock Sensor: Diagrams Knock Sensor 2 (3.7L/5.7L) 2 Way Connector (3.7L/5.7L) - (ENGINE) 2 WAY SENSOR-KNOCK 2 (3.7L/5.7L) - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way > Page 3263 Knock Sensor: Diagrams Knock Sensor 1 (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-KNOCK 1 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor - Description Knock Sensor: Description and Operation Knock Sensor - Description DESCRIPTION 3.7L - Two knock sensors (1) are bolted to the cylinder block under the intake manifold. 4.7L - One knock sensor (1) is bolted to the cylinder block under the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor - Description > Page 3266 5.7L - Two knock sensors (1) are bolted to each side of the cylinder block (outside) under each exhaust manifold (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor - Description > Page 3267 Knock Sensor: Description and Operation Knock Sensor - Operation OPERATION When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric crystal which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal 5.7L Two knock sensors (1) are used. Each sensor is bolted to the outside of the cylinder block below the exhaust manifold (3). 1. Raise the vehicle. 2. Disconnect the knock sensor electrical connector (5). 3. Remove the knock sensor mounting bolt (2). NOTE: Note the foam strip on bolt threads. This foam strip is used only to retain the bolts to the sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove the knock sensor (1) from the engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 3270 Knock Sensor: Service and Repair Knock Sensor - Installation 5.7L 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). NOTE: Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt (2). Tighten to 15 +/- 2 ft. lbs. (20 Nm) (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3274 Manifold Pressure/Vacuum Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-MAP - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3275 Manifold Pressure/Vacuum Sensor: Description and Operation OPERATION The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal 5.7L 1. Disconnect Map sensor (1) electrical connector. 2. Rotate MAP sensor (1) 1/4 turn counterclockwise for removal. 3. Lift MAP sensor (1) upward. 4. Check condition of sensor o-ring (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 3278 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 5.7L 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring (2) for cuts or tears. 3. Position MAP sensor (1) into manifold. 4. Rotate MAP sensor (1) clockwise for installation. 5. Connect electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3282 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3283 Oil Pressure Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-OIL PRESSURE - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3284 Oil Pressure Sensor: Description and Operation DESCRIPTION The oil pressure sensor uses the following three circuits: - Signal circuit to the PCM - Sensor ground circuit through the PCM - 5 volt reference circuit from the PCM The oil pressure sensor returns a voltage signal back to the PCM with reference to oil pressure. Ground for the sensor is supplied by the PCM. The oil pressure sensor is located on the right side of the engine block. The sensor screws into the engines main oil gallery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Oil Pressure Sensor - Removal Oil Pressure Sensor: Service and Repair Oil Pressure Sensor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the High Voltage Power Down Procedure . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Raise and support the vehicle. 3. Disconnect the oil pressure sensor electrical connector (1). 4. Remove the oil pressure sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Oil Pressure Sensor - Removal > Page 3287 Oil Pressure Sensor: Service and Repair Oil Pressure Sensor - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions NOTE: Apply Mopar(R) Thread Sealant with PTFE to the sensor threads before installing into the engine block. 1. Install the oil pressure sensor (1). 2. Connect the oil pressure sensor electrical connector (1). 3. Lower the vehicle. 4. Perform the High Voltage Power Up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3292 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3293 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3294 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3295 Oxygen Sensor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3296 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3297 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3298 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3299 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3300 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way Oxygen Sensor: Diagrams Oxygen Sensor 1/1 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/1 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way > Page 3303 Oxygen Sensor: Diagrams Oxygen Sensor 1/2 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/2 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way > Page 3304 Oxygen Sensor: Diagrams Oxygen Sensor 2/1 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/1 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way > Page 3305 Oxygen Sensor: Diagrams Oxygen Sensor 2/2 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/2 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3306 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3307 Oxygen Sensor: Description and Operation DESCRIPTION The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors. Federal Emission Packages : Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3308 Oxygen Sensor: Testing and Inspection CHECKING THE OXYGEN SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. OXYGEN SENSOR, WIRING, OR CONNECTORS NOTE: Diagnose and repair any O2 sensor or rationality DTCs before proceeding with this test. NOTE: When performing this procedure as part of another diagnostic process, it may be necessary to repeat this test for all of the oxygen sensors on the vehicle. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 2 2. OXYGEN SENSOR VOLTAGE 1. Start the engine and allow it to reach normal operating temperature. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 2. With a scan tool, monitor all O2 Sensor voltage readings. Is the voltage switching between 2.5 and 3.4 volts for all O2 sensors? Yes - Go to 3 - Perform the POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 4 3. O2 SENSOR HEATER OPERATION 1. Turn the ignition off. NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0 volts. 2. Turn the ignition on. 3. With a scan tool, actuate the O2 Sensor heater. 4. With the scan tool, monitor O2 Sensor voltage for at least 2 minutes. Does the voltage stay above 4.5 volts? Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3309 Yes - Go to 4 - Perform the POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Test complete. 4. O2 SENSOR 1. Turn the ignition off. NOTE: Check for contaminants that may cause improper O2 Sensor operation, such as contaminated fuel, unapproved silicone, or evidence of oil or coolant. 2. Disconnect the O2 Sensor harness connector. 3. Turn the ignition on. 4. With a scan tool, monitor the O2 Sensor voltage. NOTE: The voltage should be approximately 5.0 volts with the connector disconnected. 5. Connect a jumper wire between the signal circuit and the return circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from 5.0 volts to 2.5 volts with the jumper wire in place. Is the O2 Sensor voltage displayed on the scan tool as described? Yes - Replace the O2 Sensor. - Perform the POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 5 5. O2 SENSOR SIGNAL CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Signal circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor signal circuit for a short to ground, open circuit, short to voltage, or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 6 6. O2 SENSOR RETURN CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Return circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor return circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3310 No - Go to 7 7. POWERTRAIN CONTROL MODULE (PCM) 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the O2 sensor and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Monitor the scan tool data relative to the components tested in this procedure and wiggle test the wiring and connectors. 5. Look for the data to change or for a DTC to set during the wiggle test. 6. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Replace and program the Powertrain Control Module (PCM). - Perform the POWERTRAIN VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal REMOVAL Refer to graphic for typical O2S (oxygen sensor) locations if equipped with four oxygen sensors. Refer to graphic for typical O2S (oxygen sensor) locations if equipped with two oxygen sensors. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow the engine to cool before removing the oxygen sensor. 1. Raise and support vehicle. 2. 4-Sensor System If removing the right-upstream (2/1) sensor, remove the right-front tire/wheel, and then remove the plastic inner fender liner. 3. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on the wire going into sensor. 4. Remove O2S sensor with an oxygen sensor removal and installation tool. 5. Clean threads in exhaust pipe using appropriate tap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3313 Oxygen Sensor: Service and Repair Installation INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor and tighten to 30 ft. lbs. (41 Nm) torque. 2. Connect O2S sensor wire connector. 3. 4-Sensor System: If installing the right-upstream (2/1) sensor, install plastic inner fender liner, and right-front tire/wheel. 4. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3317 Transmission Position Switch/Sensor: Diagrams Connector (HEV) - (TRANSMISSION SIDE) 12 WAY SENSOR-TRANSMISSION RANGE (HEV) - (TRANSMISSION SIDE) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Description DESCRIPTION The transmission range sensor (2) is located inside the transmission and connects to the mainshaft (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description > Page 3320 Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Disconnect the transmission range sensor electrical connector (1). 3. Remove the bolt (1) securing the transmission range sensor (2) to the mainshaft (3). 4. Remove the mainshaft roll pin (1) from the transmission case (2) and remove the mainshaft. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3323 5. Lower the transmission range sensor (2) and remove the park actuator rod (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3324 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install the park actuator rod (3) into the transmission range sensor (2). 2. Install the mainshaft roll pin (1) to the transmission case (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3325 3. Position the transmission range sensor (2) into place in the transmission case. 4. Install the mainshaft (3) into the transmission case. 5. Install the transmission range sensor mounting bolt. Tighten the bolt to 8 Nm (71 NOTE: Before install the TEHCM / valve body assembly to the transmission case, be certain the existing gasket is in place. 6. Install the valve body. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3330 Accelerator Pedal Position Sensor: Diagrams Connector - (HEADLAMP AND DASH) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (HEADLAMP AND DASH) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (6) is attached to the accelerator pedal assembly (4) under the instrument panel. The APPS is used only with the 5.7L V-8 engine. The APPS is part of the pedal assembly and is a non-serviceable part and the pedal assembly has to be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 3333 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) is a linear potentiometer. It provides the Powertrain Control Module (PCM) with a DC voltage signal proportional to the angle, or position of the accelerator pedal. The APPS signal is translated (along with other sensors) to place the throttle plate (within the throttle body) to a pre-determined position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation Fuel Pressure Sensor/Switch: Description and Operation DESCRIPTION - HEV The fuel tank pressure sensor provides the PCM with information on vapor pressure inside the fuel tank. The sensor is a diaphragm-type pressure sensor and varies its voltage output depending on fuel tank pressure. When the fuel tank isolation valve is activated (closed), preventing fuel vapors from leaving the tank, the PCM will monitor the fuel tank pressure sensor to prevent pressure from increasing or decreasing to an unsafe level. Excessive fuel tank pressure could cause fuel vapors to vent out the fuel cap or damage system components while insufficient fuel tank pressure (vacuum) caused by lack of air entering the tank to take the place of consumed fuel could lead to collapsed tank, lines or loss of fuel pressure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor - Removal REMOVAL - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the fuel system pressure release procedure See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 3. Disconnect the 12 volt battery system ground isolation connector (1). 4. Raise and support the vehicle. 5. Disconnect the fuel fill hose (1) at the rear of the fuel tank. 6. Disconnect the fuel fill vapor line quick-connect fitting (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 3339 7. Disconnect the electrical connector at the EVAP System Integrity Monitor (ESIM) switch (2). 8. Disconnect the fuel tank isolation valve electrical connector (2) at the EVAP canister mounting bracket. 9. Disconnect the fuel tank isolation valve vapor line quick-connect fitting (1) to the purge solenoid tubing connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 3340 10. Support the fuel tank with a suitable hydraulic jack. 11. Remove the two fuel tank support strap retaining bolts (2) and position both support straps (3) aside. 12. Carefully lower the fuel tank (1) a few inches. 13. Disconnect the fuel pressure sensor electrical connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 3341 14. Thoroughly clean the area around the fuel pressure sensor. 15. Remove the fuel pressure sensor from the fuel tank (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 3342 Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor - Installation INSTALLATION - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Install the fuel pressure sensor (1) into the fuel tank. 2. Connect the fuel pressure sensor electrical connector (1). 3. Raise the fuel tank until snug to the body. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 3343 4. Position both fuel tank support straps (3), install the retaining bolts (2) and tighten to 40 Nm (30 ft. lbs.). 5. Remove the hydraulic jack. 6. Connect the fuel tank isolation valve vapor line quick-connect fitting (1) to the purge solenoid tubing connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 3344 7. Connect the fuel tank isolation valve electrical connector (2) at the EVAP canister mounting bracket. 8. Connect the electrical connector at the EVAP System Integrity Monitor (ESIM) switch (2). 9. Connect the fuel fill hose (1) at the rear of the fuel tank. 10. Connect the fuel fill vapor line quick-connect fitting (2). 11. Lower the vehicle. 12. Connect the 12 volt battery system ground isolation connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 3345 13. Connect the fuel line quick connect fitting to the fuel rail (1) See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair 14. Install the fuel fill cap. 15. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 16. Start the engine and check for leaks at all fuel tank connections. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor > Page 3351 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3352 Camshaft Position Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-CAMSHAFT POSITION - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description 5.7L The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 3355 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation 5.7L The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.7L The Camshaft Position Sensor (CMP) (3) is located on right side of timing gear/chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from timing gear/chain cover. 4. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 3358 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in timing gear/chain cover. 2. Install sensor (2) into timing gear/chain cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing gear/chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 Nm (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3362 Crankshaft Position Sensor: Diagrams Connector (5.7L) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (5.7L) - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description 5.7L The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 5.7L 1. Raise vehicle. 2. Disconnect CKP electrical connector (2) at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 3368 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking and twisting action. CAUTION: Before tightening the CKP sensor mounting bolt, be sure the sensor is completely flush to the cylinder block. If the CKP sensor is not flush, damage to the sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Removal REMOVAL 1. Disconnect negative cable from battery. 2. Remove the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 3. Remove the tilt lever handle. 4. Remove the lower shroud (2) from steering column. 5. Place shifter in PARK position. The ignition key (2) must be in the key cylinder (1) for cylinder removal. 6. A retaining pin is located at side of key cylinder assembly. a. Rotate key (2) to RUN position. b. Press in on retaining pin with a small punch (3) , while pulling key cylinder (1) from ignition switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 3374 7. Remove the key (2) and key cylinder (1) from the column (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 3375 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Installation INSTALLATION The ignition key (2) must be in the key cylinder (1) for cylinder installation. 1. Install the key cylinder (1) into the housing (3) using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder (1) in until it clicks. 3. Replace the lower shroud. 4. Install the tilt lever handle. 5. Install the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 6. Reconnect the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) Knock Sensor: Locations Knock Sensor 1 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3380 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3381 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3382 Knock Sensor: Locations Knock Sensor 2 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3383 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way Knock Sensor: Diagrams Knock Sensor 2 (3.7L/5.7L) 2 Way Connector (3.7L/5.7L) - (ENGINE) 2 WAY SENSOR-KNOCK 2 (3.7L/5.7L) - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way > Page 3386 Knock Sensor: Diagrams Knock Sensor 1 (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-KNOCK 1 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Description Knock Sensor: Description and Operation Knock Sensor - Description DESCRIPTION 3.7L - Two knock sensors (1) are bolted to the cylinder block under the intake manifold. 4.7L - One knock sensor (1) is bolted to the cylinder block under the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Description > Page 3389 5.7L - Two knock sensors (1) are bolted to each side of the cylinder block (outside) under each exhaust manifold (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor Description > Page 3390 Knock Sensor: Description and Operation Knock Sensor - Operation OPERATION When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric crystal which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal 5.7L Two knock sensors (1) are used. Each sensor is bolted to the outside of the cylinder block below the exhaust manifold (3). 1. Raise the vehicle. 2. Disconnect the knock sensor electrical connector (5). 3. Remove the knock sensor mounting bolt (2). NOTE: Note the foam strip on bolt threads. This foam strip is used only to retain the bolts to the sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove the knock sensor (1) from the engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 3393 Knock Sensor: Service and Repair Knock Sensor - Installation 5.7L 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). NOTE: Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt (2). Tighten to 15 +/- 2 ft. lbs. (20 Nm) (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE The correct fuel pressure for this vehicle is 58 psi +/- 2 psi Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3398 Fuel Pressure: Testing and Inspection FUEL PRESSURE LEAK DOWN For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: Follow these safety precautions to reduce the risk of fire and serious possible serious or fatal injury when performing this test procedure. Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. Use extreme caution when connecting and disconnecting fuel lines. - Considerable fuel leakage may occur when servicing the fuel system. Wear protective eye wear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair / replace as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A 1. Turn the ignition off. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3399 WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from Gas and Diesel Fuel Pressure/Decay Tester 8978A. Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978A-1 (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect the Reservoir Assembly 534960 (4) to the Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 3400 - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 2. Turn the ignition on, wait five seconds, turn the ignition off and then wait 1 minute before proceeding. 3. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 Kpa +/- 34 Kpa (59 psi +/- 5 psi). SRT-4 fuel pressure specification is 552 Kpa +/- 34 Kpa (80 psi +/- 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the Checking The Fuel Delivery System diagnostic procedure as directed. 5. CHECK FUEL DELIVERY SYSTEM FOR LEAK DOWN WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Close the Fuel System Isolation Valve (1) and then wait five minutes before proceeding. 2. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge (1) - Replace the fuel pump module. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Yes - On Fuel Outlet Gauge (2) - Replace the leaking fuel injector(s). - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. No - If directed here by another test, return to that test. Otherwise, test complete. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal Air Filter Element: Service and Repair Air Cleaner - Removal REMOVAL - AIR FILTER ELEMENT - HEV 1. Remove the air cleaner trim covers (2) with a small screwdriver (1). 2. Remove the air clean cover fasteners (1). 3. Unclip the air cleaner cover latches (2). 4. Remove the air cleaner cover (3). 5. Remove the air filter element (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 3406 Air Filter Element: Service and Repair Air Cleaner - Installation INSTALLATION - AIR FILTER ELEMENT - HEV 1. Install a new filter element (1). 2. Install the air cleaner cover (3). 3. Install the air cleaner cover fasteners (1). 4. Secure the air cleaner cover latches (2). 5. Install the air cleaner trim covers (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions Use the following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove the fuel fill cap. 2. Remove the fuel pump relay or the fuel pump speed relay from the Power Distribution Center (PDC) (1), refer to the label on the underside of the PDC cover for relay locations or See: Maintenance/Fuses and Circuit Breakers/Fuse/Locations/Fuse Panel 3. Start and run the engine until it stalls. 4. Attempt restarting the engine until it will no longer run. 5. Turn the ignition key to the OFF position. 6. Disconnect the 12 volt battery system ground isolation connector (1). 7. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down NOTE: Excessive fuel spillage onto the gaskets can cause gaskets to expand and dislodge from gasket groove. 8. Place a rag or towel around the fuel line quick-connect fitting at the fuel rail to prevent residual fuel spray or spillage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 3411 9. Disconnect the fuel supply line quick connect fitting at the fuel rail (1) and plug the fuel supply line with a shipping cap See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair 10. Return the fuel pump relay or the fuel pump speed relay to the PDC. NOTE: One or more Diagnostic Trouble Code(s) (DTC) may have been stored in the PCM memory due to the fuel pump relay removal. A diagnostic scan tool must be used to erase a DTC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications ENGINE FIRING ORDER - 5.7L The firing order for the 5.7L V-8 is 1-8-4-3-6-5-7-2. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > System Information > Specifications Ignition Timing: Specifications IGNITION TIMING Ignition timing is not adjustable on any of the available engines. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications Spark Plug: Specifications Spark Plug Specifications SPARK PLUGS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Spark Plug Specifications > Page 3422 Spark Plug: Specifications Torque SPARK PLUG TORQUES Spark Plugs - 3.7L................................................................................................................................ .......................................................27 Nm (20 ft. lbs.) Spark Plugs - All 4.7L (Upper or Lower row) (New plugs/gaskets).......................................................................................................27±3 Nm (20 ft. lbs.) Spark Plugs - All 4.7L (Upper or Lower row) (Used plugs/gaskets).......................................................................................................22±3 Nm (16 ft. lbs.) **Spark Plugs - 5.7L............................................................................................................................. ........................................ 18(±3) Nm (13(±2) ft. lbs.) ** Torque critical tapered design. Do not exceed 15 ft.lbs. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal Spark Plug: Service and Repair Spark Plug - Removal 5.7L 1. Remove all the necessary air filter tubing and air intake components at the top of the engine and at the throttle body See: Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal 2. Prior to removing the ignition coil, spray compressed air around the base of the ignition coil at the cylinder head. 3. Remove the ignition coil (1) See: Ignition System/Ignition Coil/Service and Repair/Ignition Coil - Removal 4. Prior to removing the spark plug, spray compressed air into the cylinder head opening. 5. Remove the spark plug from the cylinder head using a quality thin wall socket with a rubber or foam insert. 6. Inspect the spark plug condition. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 3425 Spark Plug: Service and Repair Spark Plug - Installation 5.7L CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. CAUTION: Do not attempt to clean any of the spark plugs. Replace only. 1. Check and adjust the spark plug gap with a gap gauging tool (1) See: Specifications/Spark Plug Specifications. CAUTION: Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. 2. Start the spark plug into the cylinder head by hand to avoid cross threading. NOTE: Always tighten spark plugs to the specified torque. Certain engines use torque sensitive spark plugs. Over tightening can cause distortion resulting in a change in the spark plug gap, or a cracked porcelain insulator. NOTE: Spark plugs have a torque critical tapered design. Do not exceed 20 Nm (15 ft. lbs.). 3. Tighten the spark plugs to 18 Nm (13 ft. lbs.). 4. To aid in coil installation, apply silicone based grease such as Mopar(R) Dielectric Grease into spark plug end of ignition coil rubber boots. Also apply this grease to the tops of spark plugs. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 3426 5. Install the ignition coil(s) (1) See: Ignition System/Ignition Coil/Service and Repair/Ignition Coil Installation 6. Install all necessary air filter tubing and air intake components to top of engine and to throttle body See: Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications PRESSURE/VARIATION Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3430 Compression Check: Testing and Inspection CYLINDER COMPRESSION PRESSURE LEAKAGE NOTE: The results of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions. NOTE: Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. 1. Clean the spark plug recesses with compressed air. 2. Remove the spark plugs and record the cylinder number of each spark plug for future reference. 3. Inspect the spark plug electrodes for abnormal firing indicators such as fouled, hot, oily, etc. 4. Disable the fuel system See: Fuel Filter/Fuel Pressure Release/Service and Repair and perform the fuel system pressure release procedure. 5. Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. 6. Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. NOTE: The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. 7. Compression should not be less than 689 kPa (100 psi) and not vary more than 25 percent from cylinder to cylinder. 8. If one or more cylinders have abnormally low compression pressures, repeat the compression test. NOTE: If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem in the cylinder in question. 9. If one or more cylinders continue to have abnormally low compression pressures, perform the cylinder combustion pressure leakage test See: Engine, Cooling and Exhaust/Engine/Testing and Inspection/Component Tests and General Diagnostics/Cylinder Combustion Pressure Leakage Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3435 Accelerator Pedal Position Sensor: Diagrams Connector - (HEADLAMP AND DASH) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (HEADLAMP AND DASH) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (6) is attached to the accelerator pedal assembly (4) under the instrument panel. The APPS is used only with the 5.7L V-8 engine. The APPS is part of the pedal assembly and is a non-serviceable part and the pedal assembly has to be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 3438 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) is a linear potentiometer. It provides the Powertrain Control Module (PCM) with a DC voltage signal proportional to the angle, or position of the accelerator pedal. The APPS signal is translated (along with other sensors) to place the throttle plate (within the throttle body) to a pre-determined position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3442 Intake Air Temperature Sensor: Diagrams Connector HEV - (ENGINE) 2 WAY SENSOR-INTAKE AIR TEMPERATURE HEV - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor - Description Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Description DESCRIPTION The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor - Description > Page 3445 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Operation OPERATION The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal 5.7L The intake manifold air temperature (IAT) sensor is installed into the front of the intake manifold air box plenum (1). 1. Disconnect electrical connector (2) from IAT sensor. 2. Clean dirt from intake manifold at sensor base. 3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counterclockwise for removal. 4. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 3448 Intake Air Temperature Sensor: Service and Repair Installation 5.7L 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold (1). 3. Position sensor (2) into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Front Control Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Locations > Front Control Module > Page 3453 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way Body Control Module: Diagrams Front Control Module (PDC AUX) 49 Way Connector - (PDC AUX) 49 WAY MODULE-FRONT CONTROL - (PDC AUX) 49 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 3456 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 3457 Body Control Module: Diagrams Front Control Module C1 (Headlamp And Dash) 24 Way Connector C1 - (HEADLAMP AND DASH) 24 WAY MODULE-FRONT CONTROL - (HEADLAMP AND DASH) 24 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 3458 Body Control Module: Diagrams Front Control Module C2 (Headlamp And Dash) 12 Way Connector C2 - (HEADLAMP AND DASH) 12 WAY MODULE-FRONT CONTROL - (HEADLAMP AND DASH) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 3459 Body Control Module: Diagrams Hybrid Gateway Module C1 (HEV) (Headlamp And Dash) 24 Way Connector C1 (HEV) - (HEADLAMP AND DASH) 24 WAY MODULE-HYBRID GATEWAY (HEV) - (HEADLAMP AND DASH) 24 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 3460 Body Control Module: Diagrams Hybrid Gateway Module C2 (HEV) (Headlamp And Dash) 12 Way Connector C2 (HEV) - (HEADLAMP AND DASH) 12 WAY MODULE-HYBRID GATEWAY (HEV) - (HEADLAMP AND DASH) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description Body Control Module: Description and Operation Gateway Module - Description DESCRIPTION Vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system have a Hybrid Gateway Module (HGM) (1) that is secured with three screws to the stamped steel Transmission Auxiliary Oil Pump (TAOP) control module mounting bracket located on the left hydro form (frame rail) near the back of the left front wheel housing within the engine compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum HGM housing is the electronic circuitry of the HGM, which includes a microprocessor and an electronic printed circuit board. A stamped metal cover plate (2) is sealed and secured to the HGM housing with four screws to enclose and protect the internal electronic circuitry and components. Two molded plastic electrical connectors (3), one containing 24 terminal pins and the other containing 12 terminal pins, exit the forward facing side of the HGM cover plate and are pointed downward. These terminal pins connect the HGM to the vehicle electrical system through two dedicated take outs and connectors of the headlamp and dash wire harness. The HGM housing has integral mounting flanges on two sides with three mounting holes in each flange. The mounting flange to the left of the connector receptacles is secured to the TAOP control module mounting bracket with two screws, while the flange on the right side is secured to the bracket with only one screw. The HGM cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description > Page 3463 Body Control Module: Description and Operation Front Control Module - Description DESCRIPTION The Front Control Module (FCM) is a micro controller based module located in the left front corner of the engine compartment. The front control module mates to the power distribution center to form the Integrated Power Module (IPM). The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The front control module controls power to some of these vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the CAN bus circuit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description > Page 3464 Body Control Module: Description and Operation Front Control Module - Operation OPERATION As messages are sent over the CAN bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are controlled by the FCM: - Front turn signals - Stop, turn signal and tail lamps - Front and rear hazard warning lamps - Headlamps - Fog Lamps - Daytime running lamps - if equipped - Horn - Windshield and liftgate wiper and washer systems - Transfer case shifting - Trailer tow wiring output - Rear window defroster power and timing - Air conditioning condenser cooling fan The FCM provides the following features for the above function: - It provides a illuminated approach feature that turns the headlamps on when the vehicle is unlocked with the Remote Keyless Entry (RKE) transmitter. - It flashes lamps in response to turn signal, RKE and Vehicle Theft Security System (VTSS) inputs. - It sounds the horn in response to RKE and VTSS inputs. - It turns off the horn in the event of excessively long operation that could otherwise damage the horn. - It turns off the windshield washer motor after 10 seconds of continuous operation to protect the motor. - It minimizes voltage variations to the headlamps to extend bulb life and to equalize the light output from the lamps, which might otherwise differ due to variations in wiring resistance. - If the headlamps are left on, it automatically turns them off after eight minutes to protect the battery from discharge.It monitors battery voltage and turns off non-essential functions such as the fog lamps, rear window defogger, and heated seats if necessary to conserve battery power. - It operates the high-beam headlamps at reduced intensity by pulse-width modulation of the power supply to provide the daytime running lamps. - It provides the variable delay intermittent windshield and liftgate wiper time delay features, and the vehicle speed sensitive windshield wiper delay variation. - It acts as a link between the CAN bus network for critical powertrain and anti-lock brake systems and the network for body and interior modules. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description > Page 3465 Body Control Module: Description and Operation Gateway Module - Operation OPERATION The Hybrid Gateway Module (HGM) provides a communication interface between the electronic control modules (nodes) in the vehicle, as well as with the diagnostic scan tool connected to the Controller Area Network (CAN) data bus system and the nodes connected to the Hybrid Local Area Network (H-LAN) data bus system. The HGM is the central gateway that processes and transfers messages between the different bus systems. In addition, the HGM is Local Interface Network (LIN) bus compatible. It receives a direct input over the LIN bus from a humidity sensor secured to the inside rear view mirror mount on the inside of the windshield glass, which it then transmits over the CAN data bus to other electronic modules in the vehicle. The microprocessor-based HGM also provides input and output circuitry that responds to both digital and analog inputs and provides electronically controlled higher current load outputs through lower current relay drivers. The HGM uses On-Board Diagnostics (OBD). If the HGM detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) that can be retrieved with a diagnostic scan tool through the 16-way data link connector located on the driver side lower edge of the instrument panel. The HGM connects directly to a fused battery current input and to ground, so that it remains capable of operating, regardless of the ignition switch position. The hardwired inputs and outputs for the HGM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the HGM, the electronic controls or communication between other modules and devices that provide features of the Hybrid Electric Vehicle (HEV) control system. The most reliable, efficient and accurate means to diagnose the HGM, the electronic controls and communication related to HGM operation, requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Front Control Module (FCM) Intermittent Condition Test Body Control Module: Testing and Inspection Front Control Module (FCM) Intermittent Condition Test INTERMITTENT CONDITION For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. INTERMITTENT CONDITION NOTE: The conditions that set the DTC are not present at this time. The following list may help in identifying the intermittent condition. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 1. Perform any Technical Service Bulletins (TSBs) that may apply. 2. Review the scan tool Freeze Frame information. If possible, try to duplicate the conditions under which the DTC set. 3. Turn the ignition off. 4. Visually inspect the related wire harness. Wiggle the related wire harness and look for an interrupted signal on the affected circuit. Disconnect all the related harness connectors. Look for any chafed, pierced, pinched, partially broken wires and broken, bent, pushed out, or corroded terminals. 5. Perform a voltage drop test on the related circuits between the suspected inoperative component and the Anti-Lock Brake Module, Front Control Module, or Totally Integrated Power Module, which every applies to the circuits in questions. 6. Inspect and clean all Powertrain Control Module (PCM), APS, engine, and chassis grounds that are related to the most current DTC. 7. If numerous trouble codes were set, use a wire schematic and look for any common ground or supply circuits 8. For any Relay DTCs, actuate the Relay with the scan tool and wiggle the related wire harness to try to interrupt the actuation. 9. Use the scan tool to perform a System Test if one applies to failing component. 10. A co-pilot, data recorder, and/or lab scope should be used to help diagnose intermittent conditions. Were any problems found during the above inspections? Yes - Perform the necessary repairs. - Perform the APS VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/APS Verification Test. No - Test Complete. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Front Control Module (FCM) Intermittent Condition Test > Page 3468 Body Control Module: Testing and Inspection Wireless Control Module (WCM) Intermittent Condition Test WIRELESS CONTROL MODULE (WCM) INTERMITTENT TEST For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. RECORD AND ERASE ALL WCM DIAGNOSTIC TROUBLE CODES (DTCS) Using a scan tool, record and erase all DTCs from the WCM. Monitor any active codes as you work through the following steps. - Review the code monitor and set conditions for any DTCs that are stored and attempt to reproduce the conditions listed. - Wiggle the wiring harness and connectors of the related circuit, sensor or component. - Turn the ignition off. Search for any Technical Service Bulletins (TSBs) that may apply. Was the source of the customer complaint found or did any DTCs appear and stay active? Yes - Make the appropriate repairs and perform the WIRELESS CONTROL MODULE (WCM) VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Wireless Control Module (WCM) Verification Test or select the correct DTC procedure. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. No - Go To 2 2. ATTEMPT TO REPRODUCE THE CONDITION In the event the customer complaint cannot be duplicated due to an intermittent condition in the theft/security system, the following may aid in attempting to reproduce the condition. - Using the wiring diagram/schematic as a guide, inspect the wiring and connectors related to the stored code or component in question. - Look for chafed, pierced, pinched, or partially broken wires and broken, bent, pushed out, spread, corroded, or contaminated terminals. - If the customer concern was related to a specific fobik, ensure the fobik in question is used while attempting reproduce the condition. - Reconnect any disconnected components and harness connectors and ensure they are properly seated. - If numerous trouble codes were set, use a schematic and inspect any common ground or supply circuits. Was the source of the intermittent condition located? Yes - Make the appropriate repairs and perform the WIRELESS CONTROL MODULE (WCM) VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Wireless Control Module (WCM) Verification Test No - The problem cannot be found at this time. If repeated intermittent failures are encountered that cannot be reproduced and the condition has prompted multiple customer visits to the dealership, document any findings on the repair order. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Front Control Module (FCM) Intermittent Condition Test > Page 3469 Body Control Module: Testing and Inspection Wireless Control Module (WCM) Pre-Diagnostic Procedure WIRELESS CONTROL MODULE (WCM) PRE-DIAGNOSTIC PROCEDURE Before attempting to repair any theft or security system, technicians should be familiar with and fully understand the system operation. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Description and Operation/Vehicle Theft Security System - Description. The following should be used as a checklist to be completed in its entirety prior to referencing specific Theft and Security Diagnostic Procedures. FOLLOW THE BASIC OUTLINE IN THE SIX-STEP TROUBLESHOOTING PROCEDURE - Verification of complaint - Verification of any related symptoms - Symptom analysis - Problem isolation - Repair of isolated problem - Verification of proper operation TAKE INTO ACCOUNT CURRENT VEHICLE CONDITION, REPAIR HISTORY, AND TECHNICAL SERVICE BULLETINS (TSBs) - Verify there are no outward signs of vehicle damage that could impact the proper operation of the theft or security system. Check for aftermarket vehicle accessories that may have been installed improperly or could interfere with the system - Check the vehicle repair history for repairs that may relate to the current condition. - Perform a check of current Technical Service Bulletins (TSB) for the system related to the customer concern. If a TSB applies, follow the procedure outlined in the TSB. DIAGNOSE ONLY THOSE FAILURES THAT ARE ACTIVE AND CAN BE REPRODUCED - Check the control module central to the subsystem that is exhibiting the condition for active Diagnostic Trouble Codes (DTCs). - For an intermittent failure that is not current at the time of vehicle inspection, refer to the WIRELESS CONTROL MODULE INTERMITTENT TEST See: Wireless Control Module (WCM) Intermittent Condition Test and document the event on the repair order. ADDRESS ACTIVE DTCS IN THE CORRECT ORDER - Low/High Voltage and Serial Data Loss of Communication Codes - Module Internal Failure and Configuration Mismatch Codes - Circuit specific DTC failures As a general rule, for any theft/security system control module that exhibits more than one active DTC, address the codes in the order indicated; should the malfunction still be present after conducting this Pre-diagnostic Procedure, technicians should continue to the appropriate DTC procedure or symptom diagnostic. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal Body Control Module: Service and Repair Gateway Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. A technician trained in proper Hybrid Electric Vehicle (HEV) service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. Unlatch and remove the Power Distribution Center (PDC) from the PDC mounting bracket on the left hydro form (frame rail) over the left front wheel house in the engine compartment. Move the PDC forward far enough to access the Hybrid Gateway Module (HGM) (1). 3. Remove the three screws (2) that secure the HGM to the Transmission Auxiliary Oil Pump (TAOP) control module mounting bracket (3) that is secured to the left hydro form near the back of the left front wheel house. 4. Disconnect the two headlamp and dash wire harness connectors (4) from the HGM connector receptacles located on the forward facing side of the module. 5. Remove the HGM from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal > Page 3472 Body Control Module: Service and Repair Gateway Module - Installation INSTALLATION 1. Position the Hybrid Gateway Module (HGM) (1) near the Transmission Auxiliary Oil Pump (TAOP) control module mounting bracket (3) that is secured to the left hydro form (frame rail) near the back of the left front wheel house in the engine compartment. 2. Reconnect the two headlamp and dash wire harness connectors (4) to the HGM connector receptacles located on the forward facing side of the module. 3. Position the HGM to the TAOP control module mounting bracket. 4. Install and tighten the three screws (2) that secure the HGM to the mounting bracket. Tighten the screws securely. 5. Reinstall the Power Distribution Center (PDC) onto the PDC mounting bracket on the left hydro form over the left front wheel house in the engine compartment. Be certain that each of the PDC latches is fully engaged with the mounting bracket. 6. Reconnect the battery negative cable. A technician trained in proper Hybrid Electric Vehicle (HEV) service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal > Page 3473 Body Control Module: Service and Repair Front Control Module - Removal REMOVAL 1. Disconnect the positive and negative battery cables from the battery. 2. Partially remove the Integrated Power Module (IPM) from the engine compartment. 3. Remove the front control module retaining screws. 4. Pull the front control module straight from the IPM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal > Page 3474 Body Control Module: Service and Repair Front Control Module - Installation INSTALLATION 1. Press the Front Control Module (FCM) onto the Integrated Power Module (IPM). 2. Install the mounting fasteners. 3. Install the IPM. 4. Connect the positive and negative battery cables. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor > Page 3479 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3480 Camshaft Position Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-CAMSHAFT POSITION - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description 5.7L The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 3483 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation 5.7L The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.7L The Camshaft Position Sensor (CMP) (3) is located on right side of timing gear/chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from timing gear/chain cover. 4. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 3486 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in timing gear/chain cover. 2. Install sensor (2) into timing gear/chain cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing gear/chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 Nm (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3490 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3491 Coolant Temperature Sensor/Switch (For Computer): Diagrams Connector - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3495 Crankshaft Position Sensor: Diagrams Connector (5.7L) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (5.7L) - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description 5.7L The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 3498 Crankshaft Position Sensor: Description and Operation Operation 5.7L Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On the 5.7L V-8 engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 5.7L 1. Raise vehicle. 2. Disconnect CKP electrical connector (2) at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 3501 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking and twisting action. CAUTION: Before tightening the CKP sensor mounting bolt, be sure the sensor is completely flush to the cylinder block. If the CKP sensor is not flush, damage to the sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 3505 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 3506 Data Link Connector: Diagrams Connector - (INSTRUMENT PANEL) 16 WAY DATA LINK CONNECTOR - (INSTRUMENT PANEL) 16 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Data Link Connector - Description Data Link Connector: Description and Operation Data Link Connector - Description DESCRIPTION The Data Link Connector (DLC) (2) is a 16-way molded plastic connector insulator on a dedicated take out of the instrument panel wire harness. This connector is located at the lower edge of the instrument panel, outboard of the steering column. The connector insulator is retained by integral snap features within a rectangular cutout in the lower instrument panel reinforcement, just below the park brake release handle (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Description and Operation > Data Link Connector - Description > Page 3509 Data Link Connector: Description and Operation Data Link Connector - Operation OPERATION The Data Link Connector (DLC) is an industry-standard 16-way connector that permits the connection of a diagnostic scan tool to the Controller Area Network (CAN) data bus for interfacing with, configuring, and retrieving Diagnostic Trouble Code (DTC) data from the electronic modules that reside on the data bus network of the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Indicator > Component Information > Description and Operation > ETC Indicator - Description Electronic Throttle Control Indicator: Description and Operation ETC Indicator - Description DESCRIPTION An Electronic Throttle Control (ETC) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with ETC, this indicator is electronically disabled. This indicator is located in the center of the speedometer, in the area to the right of the speedometer needle hub. The ETC indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Electronic Throttle Control in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ETC indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Electronic Throttle Control Indicator > Component Information > Description and Operation > ETC Indicator - Description > Page 3514 Electronic Throttle Control Indicator: Description and Operation ETC Indicator - Operation OPERATION The Electronic Throttle Control (ETC) indicator gives an indication to the vehicle operator when the ETC system, or a circuit or component of the system is ineffective. The ETC indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The ETC indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the ETC indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the ETC indicator illuminates for about 15 seconds. The entire bulb test is a function of the PCM. - ETC Indicator Lamp-On Message - Each time the cluster receives an electronic ETC indicator lamp-on message from the PCM, the ETC indicator illuminates. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM message. The indicator remains illuminated solid or continues to flash for about 12 seconds or until the cluster receives a lamp-off message from the PCM, whichever is longer. If the indicator is illuminated solid with the engine running the vehicle will usually remain drivable. If the indicator is flashing with the engine running the vehicle may require towing. A flashing indicator means the ETC system requires immediate service. The indicator is extinguished when the ignition switch turns to the off position. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the PCM for three consecutive seconds, the ETC indicator illuminates. The indicator remains illuminated until the cluster receives a single lamp-off message from the PCM. - Self Test - Each time the cluster is put through the self test, the ETC indicator is turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the ETC indicator is a function of the PCM. The PCM continually monitors the ETC system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the PCM sends a lamp-on message after the bulb test, it indicates that the PCM has detected an ETC system malfunction or that the ETC system is ineffective. The PCM stores a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ETC indicator fails to illuminate due to an open or short in the cluster ETC indicator circuit, the cluster sends a message notifying the PCM of the condition, then the instrument cluster and the PCM will each store a DTC. Using a diagnostic scan tool for proper diagnosis of the ETC system, the PCM, the CCN, the CAN data bus or the electronic communication related to ETC indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3518 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way Engine Control Module: Diagrams Powertrain Control Module C1 38 Way Connector C1 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3521 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3522 Engine Control Module: Diagrams Powertrain Control Module C2 38 Way Connector C2 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3523 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3524 Engine Control Module: Diagrams Powertrain Control Module C3 38 Way Connector C3 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3525 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3526 Engine Control Module: Diagrams Powertrain Control Module C4 38 Way Connector C4 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3527 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description Engine Control Module: Description and Operation Powertrain Control Module - Description PCM POWERTRAIN CONTROL MODULE (PCM) The PCM (2) is attached to the right-front inner fender (1) located in the engine compartment. Modes of Operation MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3530 - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The O2S sensor heater element is energized via the ASD relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Starter motor relay - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the clutch relay. This is done if A/C has been selected by the vehicle operator and requested by the A/C thermostat. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3531 - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3532 If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5V Power Supplies 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Ignition Circuit Sense IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Powertrain Control Module (PCM). Battery voltage is supplied to the PCM through the ignition switch when the ignition is in the Run or Start position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Power Grounds POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Sensor Return SENSOR RETURN Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3533 The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. For more information, See: . Signal Ground SIGNAL GROUND Signal ground provides a low noise ground to the data link connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3534 Engine Control Module: Description and Operation Powertrain Control Module - Operation PCM POWERTRAIN CONTROL MODULE (PCM) The PCM is a pre-programmed, microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - Accelerator pedal position sensor (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CAN bus (+) circuits - CAN bus (-) circuits - Camshaft position sensor signal - Clutch Interlock Switch (if equipped) - Crankshaft position sensor - Data link connection for diagnostic scan tool - EGR position sensor (if equipped) - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensor(s) (if equipped) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure sensor - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission output speed sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3535 NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - CAN bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for diagnostic scan tool - Double start override (if equipped) - EGR valve control solenoid (if equipped) - Electronic throttle control - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle air control (IAC) motor - Ignition coil(s) - CAN bus circuits - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CAN bus circuits. - Overdrive indicator lamp (if equipped) - Radiator cooling fan (if equipped) - Speed control vacuum solenoid - Speed control vent solenoid - Starter relay - Tachometer (if equipped). Driven through CAN bus circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid 5V Power Supplies 5 VOLT SUPPLIES Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (if equipped with an RE automatic transmission). Ignition Circuit Sense IGNITION CIRCUIT SENSE The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3536 Engine Control Module: Testing and Inspection CHECKING THE PCM POWER AND GROUND CIRCUITS For a complete wiring diagram refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. PCM WIRING OR CONNECTORS 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and each connector at the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. No - Go To 2 2. CHECKING THE PCM GROUND CIRCUITS 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to 12 volts, check the PCM ground circuits. 3. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go To 3. No - Repair the PCM ground circuit(s) for an open circuit or high resistance. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3537 3. CHECKING THE PCM FUSED IGNITION CIRCUITS CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 1. Turn the ignition on. 2. Using a 12 volt test light connected to ground, check the PCM Fused Ignition circuits. 3. Check each circuit with the ignition on, engine running position, and during cranking. 4. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go To 4. No - Repair the open or short to ground in the PCM Fused Ignition circuits. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. 4. CHECKING THE PCM FUSED B+ CIRCUITS 1. Turn the ignition off. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3538 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to Ground, check the PCM Fused B+ circuits. 3. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright with the ignition on and not illuminated with the ignition off. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated as described above? Yes - Test complete. No - Repair the open or short to ground in the PCM Fused B+ circuit(s) for as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Resolver Learn STANDARD PROCEDURE - RESOLVER LEARN RESOLVER OFFSET LEARN TRIGGER EVT AHS-T TRANSMISSION The Resolver Offset Learn Trigger Procedure requires the use of a scan tool. This program allows the electronic variable transmission (EVT) AHS-T to re-calibrate itself. This will provide the proper transmission operation. The resolver offset learn procedure should be performed if any of the following procedures are performed: - Transmission Assembly Replacement - Transmission Electronic Hydraulic Control Module (TEHCM) Replacement - Flashing the TCM - Electric Motors Replacement - Valve Body Replacement or Recondition To perform the Resolver Offset Learn Trigger Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The shift lever position must stay in PARK until prompted to shift. - The calculated oil temperature must be above 15° C (60° F) and below 93° C (200° F) TCM Quick Learn QUICK LEARN TCM QUICK LEARN RFE and RLE The quick learn procedure requires the use of a scan tool. This program allows the electronic transmission system to re-calibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: - Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool indicates the procedure is complete - The calculated oil temperature must be above 15° C (60° F) and below 93° C (200° F) TCM Drive Learn DRIVE LEARN RFE and RLE When a transmission is repaired and a Quick Learn procedure has been performed on the Transmission Control Module (TCM), the following Drive Learn procedure can be performed to fine tune any shifts which are particularly objectionable. NOTE: It is not necessary to perform the complete Drive Learn procedure every time the TCM is Quick Learned. Perform only the portions which target the objectionable shift. LEARN A SMOOTH 1ST NEUTRAL TO DRIVE SHIFT Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3541 Perform this procedure only if the complaint is for a delayed or harsh shift the first time the transmission is put into gear after the vehicle is allowed to set with the engine not running for at least 10 minutes. Use the following steps to have the TCM learn the 1st N-D UD CVI. NOTE: The transmission oil temperature must be between 27-43° C (80-110° F). 1. Start the engine only when the engine and ignition have been off for at least ten (10) minutes. 2. With the vehicle at a stop and the service brake applied, record the 1st N-D UD CVI while performing a Neutral to Drive shift. The 1st N-D UD CVI accounts for air entrapment in the UD clutch that may occur after the engine has been off for a period of time. 3. Repeat 1 and 2 until the recorded 1st N-D UD CVI value stabilizes. NOTE: It is important that this procedure be performed when the transmission temperature is between 27-43° C (80-110° F). If this procedure takes too long to complete fully for the allowed transmission oil temperature, the vehicle may be returned to the customer with an explanation that the shift will improve daily during normal vehicle usage. The TCM also learns at higher oil temperatures, but these values (line pressure correction values) are not available for viewing on the scan tool. LEARN A SMOOTH NEUTRAL TO DRIVE GARAGE SHIFT Perform this procedure if the complaint is for a delayed or harsh shift when the transmission is put into gear after the vehicle has had its first shift. Use the following steps to have the TCM learn the Norm N-D UD CVI. NOTE: The transmission oil temperature must be between 27-43° C (80-110° F) to learn the UD CVI. Additional learning occurs at temperatures as low as -18° C (0° F) and as high as 93° C (200° F). This procedure may be performed at any temperature that experiences poor shift quality. Although the UD CVI may not change, shift quality should improve. 1. Start the vehicle engine and shift to drive. 2. Move the vehicle forward to a speed of at least 16 km/h (10 MPH) and come to a stop. This ensures no air is present in the UD hydraulic circuit. 3. Perform repeated N-D shifts at a stop while pausing in Neutral for at least 2-3 seconds and monitor Norm N-D UD CVI volume until the value stabilizes. The value will change during the N-D shift. This is normal since the UD value is different for the N-D shift then the normal value shown which is used for 4-3 coastdown and kick downs. Perform repeated shifts in this temperature range until the Norm N-D UD CVI value stabilizes and the N-D shifts become smooth. LEARN THE 1ST 2-3 SHIFT AFTER A RESTART OR SHIFT TO REVERSE Use the following steps to have the TCM learn the 1st 2-3 shift OD CVI. NOTE: The transmission oil temperature must be above 27° C (80° F). 1. With the vehicle engine running, select reverse gear for over 2 seconds. 2. Shift the transmission to Drive and accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform a 2-3 shift while noting the 1st 2-3 OD CVI. 3. Repeat 1 and 2 until the 1st 2-3 upshift becomes smooth and the 1st 2-3 OD CVI stabilizes. LEARN A SMOOTH 2-3 AND 3-4 UPSHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the OD and 4C CVI's. 1. Accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform multiple 1-2, 2-3, and 3-4 upshifts. The 2nd 2-3 shift following a restart or shift to reverse will be shown during the shift as a value between the 1st 2-3 OD CVI and the normal OD CVI. Updates to the normal OD CVI will occur after the 2nd shift into 3rd gear, following a restart or shift to reverse. 2. Repeat 1 until the 2-3 and 3-4 shifts become smooth and the OD and 4C CVI become stable. LEARN A SMOOTH 4-3 COASTDOWN AND PART THROTTLE 4-3 KICKDOWN NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the UD shift volume. 1. At a vehicle speed between 64-97 km/h (40-60 MPH), perform repeated 4-3 kickdown shifts. 2. Repeat 1 until the UD volume becomes somewhat stable and the shift becomes smooth. LEARN A SMOOTH 1-2 UPSHIFT AND 3-2 KICKDOWN Use the following steps to have the TCM learn the 2C shift volume. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3542 NOTE: The transmission oil temperature must be above 43° C (110° F). 1. With a vehicle speed below 48 km/h (30 MPH) and the transmission in 3rd gear, perform multiple 3-2 kick downs. 2. Repeat 1 until the 3-2 kick downs become smooth and the 2C CVI becomes stable. LEARN A SMOOTH MANUAL 2-1 PULLDOWN SHIFT AS WELL AS A NEUTRAL TO REVERSE SHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the LR volume. 1. With the vehicle speed around 40-48 km/h (25-30 MPH) in Manual 2nd, perform manual pulldowns to Low or 1st gear at closed throttle. 2. Repeat 1 until the LR CVI becomes stable and the manual 2-1 becomes smooth. LEARN A SMOOTH NEUTRAL TO REVERSE SHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). 1. With the vehicle at a stop, perform Neutral to Reverse shifts until the shift is smooth. An unlearned Neutral to Reverse shift may be harsh or exhibit a double bump. 2. If any of the shifts are still not smooth after the clutch volume stabilizes, an internal transmission problem may be present. LEARN A SMOOTH 4-5 UPSHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the Alt 2C CVI. 1. Accelerate the vehicle through 88 km/h (55 mph) at a steady 10-15 degree throttle opening and perform multiple 4-5 upshifts. 2. Repeat 1 until the 4-5 shift become smooth and the Alt 2C CVI become stable. There is a separate 2C volume used and learned for 4-5 shifts, 2CA. It is independent of the 2C CVI learned on 3-2 kick downs. PCM/ECM Reprogramming PCM/ECM REPROGRAMMING - GAS PCM / TCM FLASH REPROGRAMING This procedure will need to be done when one or more of the following situations are true: 1. A vehicle's Powertrain control module (PCM) has been replaced. 2. A diagnostic trouble code (DTC) is set "P1602 - PCM Not Programmed." 3. An updated calibration or software release is available for either the PCM or TCM ECUs. This procedure assumes that the StarSCAN(R) and StarMOBILE(R) devices are configured to your dealership's network with either a wired or wireless connection. The StarSCAN(R) and StarMOBILE(R) must also be running at the latest operating system and software release level. For more help on how to network your StarSCAN(R) or StarMOBILE(R) reference the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation' under the Download Center. Table of contents 1. SECTION 1 - PCM / TCM FLASH PROCEDURE SECTION 1 - PCM / TCM FLASH PROCEDURE 2. REQUIRED TOOLS/EQUIPMENT REQUIRED TOOLS/EQUIPMENT: 3. TECH TIPS and INFORMATIONTECH TIPS and INFORMATION: 4. PARTS REQUIRED PARTS REQUIRED SECTION 1 - PCM / TCM FLASH PROCEDURE If using StarSCAN(R) or StarMOBILE(R) Desktop Client. Go to REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client If using StarMOBILE(R) Stand-alone Diagnostic Mode. Go To REPAIR PROCEDURE - Using StarMOBILE(R) Stand-alone Diagnostic Mode REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3543 NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the StarSCAN(R) or StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power on the StarSCAN(R) or StarMOBILE(R). If the StarMOBILE(R) is being used, launch the StarMOBILE(R) Desktop Client and connect to the appropriate StarMOBILE(R) device. 4. Retrieve the old ECU part number. From the tool's Home screen, a. Select "ECU View" b. Select "PCM" c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the Flash PCM screen for later reference. 5. Program the ECU as follows: a. Using the StarSCAN(R) / StarMOBILE(R) at the Home screen, select "ECU View" b. Select "PCM" c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File" and follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 4e, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. g. Select "Download to Scantool" h. Once the download is complete, select "Close" and then "Back" i. Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. j. When the PCM update is complete, select "OK" k. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 6. Continue to SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 7. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See Section 3 SECTION 3 - AUTHORIZED MODIFICATION LABEL for details). REPAIR PROCEDURE - Using StarMOBILE(R) Stand-alone Diagnostic Mode NOTE: StarMOBILE(R) Stand-alone Mode is an efficient way to flash ECUs without having direct access to a network connection. It involves first copying the flash file to the StarMOBILE(R) device which DOES require a network connection. Once the file has been copied to the StarMOBILE(R) device, it can be used in a Stand-alone mode to flash the ECU WITHOUT a network connection. NOTE: StarMOBILE(R) does not need to be connected to a vehicle when retrieving a flash file for Stand-alone Mode. 1. Power on the StarMOBILE(R). Launch the StarMOBILE(R) Desktop Client and connect to the tool. 2. At the Home screen, select "ECU View" a. Select "PCM" b. Select "More Options" c. Select "ECU Flash" d. Select "Browse for New File" and follow the on screen instructions. e. Highlight the appropriate calibration based on the current ECU part number, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. 3. From the Flash File List, select the appropriate calibration for the PCM and select "Download to Client" 4. Once the download is complete, hit "OK" and then "Manage Files" Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3544 5. In the Manage Files screen, highlight the downloaded flash file and select "Copy to SM Device". A green check mark should now appear in the On SM Device column. 6. Exit the StarMOBILE(R) Desktop Client application. 7. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 8. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 9. On the StarMOBILE(R) device, select "Enter Stand-alone Diagnostic Mode" (use the right function key). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3545 NOTE: If a StarMOBILE(R) Desktop Client is still associated with the device, you will receive the following error: "Your StarMOBILE(R) device is currently locked by a pc named 'xxxxxxxx' on your network. To remove the lock, close its Desktop Client or reboot this device". 10. Program the ECU as follows: a. Select "ECU View" b. Select "PCM" c. Select "Flash ECU" d. Record the ECU part number at the very top of the screen for later reference. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3546 e. Highlight the flash file that you want to use. Hit "SELECT" and then "OK". Follow the on screen instructions. f. Once the flash is complete, verify that the part number at the top of the Flash PCM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 11. Continue to Section 2SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 12. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See Section 3 SECTION 3 - AUTHORIZED MODIFICATION LABEL for details). SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES Find the PCM/TCM Type for the vehicle, read and write down the steps, and then go to the step by step instructions for additional information on how to perform these procedures. STEP-BY-STEP INSTRUCTIONS If a NGC3 or NGC4 PCM was replaced, perform the following additional steps and/or routines: 1. PCM Replaced - if WCM equipped 2. Learn ETC - if ETC equipped 3. Check PCM Odometer 4. Check PCM VIN - if NOT WCM equipped 5. Quicklearn - if EATX equipped If a GPEC PCM was replaced, perform the following additional steps and/or routines: 1. If the vehicle is equipped with a CVT, ensure that the TCM has the latest software calibration available (if the vehicle is not equipped with a CVT, skip to Step 3). 2. PCM Replaced - if WCM equipped Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3547 3. Learn ETC 4. Check PCM Odometer 5. Check PCM VIN - if NOT WCM equipped 6. TCM Quicklearn - if EATX equipped If a CVT TCM was replaced, perform the following additional steps and/or routines: 1. Initialize CVT If an EGS TCM was replaced, perform the following additional steps and/or routines: 1. Initialize EGS STEP-BY-STEP INSTRUCTIONS Check PCM Odometer From the "Home" screen, select "ECU View". - Select "PCM" - Select "Misc. Functions" - Select "Check PCM Odometer" and follow the on screen instructions. - When complete, select "Finish". Check PCM VIN From the "Home" screen, select "ECU View" - Select "PCM" - Select "Misc. Functions" - Select "Check PCM VIN" and follow the on screen instructions. - When complete, select "Finish" Initialize CVT From the "Home" screen, select "ECU View" - Select "TCM" - Select "Misc. Functions" - Select "Initialize CVT" and follow the on screen instructions. - When complete, select "Finish" Initialize EGS From the "Home" screen, select "ECU View" - Select "TCM" - Select "Misc. Functions" - Select "Initialize EGS" and follow the on screen instructions. - When complete, select "Finish" Learn ETC From the "Home" screen, select "ECU View" - Select "PCM" - Select "Misc. Functions" - Select "Learn ETC" and follow the on screen instructions. - When complete, select "Finish" PCM Replaced The vehicle pin (Personal Identification Number) will be required to complete the routine. This information may be obtained in three ways: 1. The original selling invoice 2. Dealer CONNECT > Parts > Key Codes Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3548 3. Contacting the District Manager. From the "Home" screen, select "ECU View" - Select "WCM" - Select "Misc. Functions" - Select "PCM Replaced" and follow the on screen instructions. - When complete, select "Finish" Quicklearn From the "Home" screen, select "ECU View" - Select "PCM" - Select "Misc. Functions" - Select "Quicklearn" and follow the on screen instructions. - When complete, select "Finish" Update CVT TCM From the "Home" screen: - Select "ECU View" - Select "TCM" - Select "More Options" - Select "ECU Flash" - Select "Browse for New File" and follow the on screen instructions. - Highlight the appropriate calibration. - Select "Download to Scantool" - Once the download is complete, select "Close" and then "Back" - Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. - When the TCM update is complete, select "OK" - Verify that the part number at the top of the "Flash TCM" screen has updated to the latest level. SECTION 3 - AUTHORIZED MODIFICATION LABEL NOTE: The following step is required by law when reprogramming a PCM and/or TCM. Type the necessary information on the "Authorized Modification Label" and attach near the VECI label. 1. Powertrain Control / Transmission Control Module Part Numbers (Insert P/Ns) Used 2. Change Authority: TSB XX--XX 3. Dealer Code: XXXXX 4. Date: XX-XX-XX REQUIRED TOOLS/EQUIPMENT: TECH TIPS and INFORMATION: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3549 1. StarMOBILE(R) Stand-alone Diagnostic Mode is an efficient way to flash ECUs without having direct access to a network connection. It involves first copying the flash file to the StarMOBILE(R) device which DOES require a network connection. Once the file has been copied to the StarMOBILE(R) device, it can be used in a Stand-alone mode to flash the ECU WITHOUT a network connection. 2. To use the StarMOBILE(R) in Pass-Through Mode requires that your StarMOBILE(R) is connected to the dealerships network via a wired or wireless connection. For more information on how to use the StarMOBILE in Pass-Through Mode see the StarMOBILE(R) training tutorials available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Training Aids' link under the 'Training Aids' link. 3. StarMOBILE(R) does not need to be connected to a vehicle when retrieving a flash file for Stand-alone Mode. 4. Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The ECU can only be reprogrammed to a more recent version of that calibration. 5. If the flash process is interrupted or aborted, the flash should be restarted. 6. Due to the PCM / TCM programming procedure, a DTC may be set in other ECUs within the vehicle. Some DTCs may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 7. When replacing a GPEC PCM for a vehicle that is equipped with a CVT, it is extremely important that the PCM and TCM both have the latest software calibrations. 8. Do not allow the battery charger to time out or the charging rate to climb above 13.5 volts during the flash process. 9. The StarSCAN(R) and StarMOBILE(R) diagnostic tools fully support Internet connectivity and must be configured for your dealership's network. For help on setting up your StarSCAN(R) / StarMOBILE(R) for the dealership's network, refer to the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation' under the download center. 10. The operating software in the StarSCAN(R) and StarMOBILE(R) must be programmed with the latest software release level. The software level is visible in the blue header at the top of the StarSCAN(R) and StarMOBILE(R) Desktop Client screens. For instructions on how to update your scan tool, refer to the StarSCAN(R) / StarMOBILE(R) Software Update guide available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation' under the download center. PARTS REQUIRED SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3550 lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3551 - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3552 Engine Control Module: Removal and Replacement Powertrain Control Module - Removal REMOVAL CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. The PCM (2) is attached to the right-front inner fender (1) located in the engine compartment. To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect and isolate the negative battery cable. 2. Remove both wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal. 3. Remove wiper cowl (two screws, four pins). 4. Remove wiper cowl support (three bolts). 5. Remove air intake tube (four nuts). 6. Carefully unplug the four 38-way connectors (3) from PCM. 7. Remove three PCM mounting bolts (4), and remove PCM from vehicle. Powertrain Control Module - Installation INSTALLATION CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3553 1. Position PCM (2) to vehicle. 2. Install three PCM mounting bolts (4). 3. Tighten bolts to 3-5 Nm (30-40 in. lbs.). 4. Check pin connectors in the PCM. Also check the four 38-way connectors (3) for corrosion or damage. Repair as necessary. 5. Install the four 38-way connectors (3) to PCM. 6. Install air intake tube (four nuts). 7. Install wiper cowl support (three bolts). 8. Install wiper cowl (two screws, four pins). 9. Install both wiper arms. 10. Connect negative battery cable. 11. Use the diagnostic scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3557 Fuel Level Sensor: Diagrams Connector - (CHASSIS) 4 WAY MODULE-FUEL PUMP - (CHASSIS) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Level Sensor: Description and Operation Fuel Pump Module - Description DESCRIPTION The fuel pump module assembly (4) is located on the top of the fuel tank (2). The module assembly (5) contains the following components: - An internal fuel filter - A separate fuel pick-up, or inlet filter (3) - A fuel pressure regulator (4) - An electric fuel pump (2) - A lock ring to retain pump module to tank - A soft gasket between tank flange and module - A fuel gauge sending unit (fuel level sensor) (1) - Fuel line connection (6) If the fuel gauge sending unit, electrical fuel pump, primary inlet filter, fuel filter or fuel pressure regulator require service, the fuel pump module must be replaced. Electric Fuel Pump The electric fuel pump is located inside of the fuel pump module. A 12 volt, permanent magnet, electric motor powers the fuel pump. The electric fuel pump is not a separate, serviceable component. Fuel Filters Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3560 Two fuel filters are used. One is located at the bottom of the fuel pump module. The other is located inside the module. A separate frame mounted fuel filter is not used with any engine. Both fuel filters are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator The fuel pressure regulator is located within fuel pump module. Fuel Gauge Sending Unit (Fuel level sensor) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3561 Fuel Level Sensor: Description and Operation Variable Speed Fuel Pump Module (HEV) Description DESCRIPTION - HEV The variable speed fuel pump module (5) is located on the top of the fuel tank and contains the following: - Internal fuel filter - Separate fuel pick-up, or inlet filter (3) - Fuel pressure regulator (4) - Variable speed fuel pump (2) - Lock ring to retain the pump module to the tank - O-ring gasket between the tank flange and pump module - Fuel gauge sending unit (fuel level sensor) (1) - Fuel line connection (6) If the fuel gauge sending unit (fuel level sensor), variable speed fuel pump, primary inlet filter, fuel filter or fuel pressure regulator require service, the variable speed fuel pump module must be replaced as a unit. Variable Speed Fuel Pump The Hybrid Electric Vehicle (HEV) uses a variable speed fuel pump module, an additional fuel pump speed relay and a resistor to provide low speed capability to the fuel pump system. A diagnostic monitor circuit allows the PCM to verify operation of the following two circuits: - Fuel pump relay control circuit which results in closing the fuel pump relay allowing current to flow through the fuel pump speed relay for high speed fuel pump operation. - Fuel pump speed relay control circuit which results in closing the fuel pump relay and fuel pump speed relay allowing current to flow through the resistor for low speed fuel pump operation. The variable speed fuel pump is not a separate, serviceable component. Fuel Filters Two fuel filters are used. One is located at the bottom of the fuel pump module. The other is located inside the module. A separate frame mounted fuel filter is not used. Both fuel filters are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator The fuel pressure regulator is located within the fuel pump module and is not a separate, serviceable component. Fuel Gauge Sending Unit (fuel level sensor) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, a float arm, and a variable resistor track (card). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Level Sensor: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: The fuel system is under a constant pressure, even with the engine off. Before servicing the fuel pump module, the fuel system pressure must be released. 1. Perform the fuel system pressure release procedure See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect and isolate the negative battery cable. 3. Drain and remove the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank Removal 4. Note the rotational position of the module before attempting removal. An indexing arrow is located on top of the module for this purpose. 5. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 6. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 7. Rotate the breaker bar counterclockwise to remove the lock ring. 8. Remove the lock ring. The module will spring up slightly when the lock ring is removed. 9. Remove the module from the fuel tank. Be careful not to bend the float arm during removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3564 Fuel Level Sensor: Service and Repair Fuel Pump Module - Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position the fuel pump module into the opening of the fuel tank. 2. Rotate the module until the embossed alignment arrow points to the center alignment mark. This step must be performed to prevent the float from contacting the side of the fuel tank. Also be sure the fuel fitting on top of the pump module is pointed to the left side of the vehicle. 3. Position the lock ring (5) over the top of the fuel pump module. 4. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 5. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 6. Tighten the lock ring (clockwise) until all seven notches have engaged. 7. Install the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation 8. Lower the vehicle. 9. Connect the fuel line quick connect fitting to the fuel rail (1)See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair 10. Connect the negative battery cable. 11. Install the fuel fill cap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3565 Fuel Level Sensor: Service and Repair Variable Speed Fuel Pump Module (HEV) - Removal REMOVAL - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: The fuel system is under a constant pressure, even with the engine off. Before servicing the fuel pump module, the fuel system pressure must be released. 1. Perform the fuel system pressure release procedure See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 3. Disconnect the 12 volt battery system ground isolation connector (1). 4. Drain the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Procedures for Draining Fuel Tank HEV procedure. 5. Remove the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal NOTE: Prior to removing the variable speed fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. CAUTION: An indexing arrow is located on top of the variable speed fuel pump module to clock it's position into the fuel tank, note it's location for reassembly. 6. Position the lock ring remover/installer 9340 (1) into the notches on the outside edge of the lock ring (2). 7. Install a 1/2 inch drive breaker bar (4) into the lock ring remover/installer 9340 (1). NOTE: The variable speed fuel pump module will spring up slightly when the lock ring is removed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3566 8. Rotate the breaker bar counterclockwise and remove the lock ring. CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 9. Remove the variable speed fuel pump module (3) from the fuel tank. Be careful not to bend the float arm during removal. 10. Remove and discard the rubber O-ring seal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3567 Fuel Level Sensor: Service and Repair Variable Speed Fuel Pump Module (HEV) - Installation INSTALLATION - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Using a new rubber O-ring seal, position the variable speed fuel pump module into the opening of the fuel tank. 2. Rotate the variable speed fuel pump module until the embossed alignment arrow points to the center alignment mark as noted during disassembly. This step must be performed to prevent the float from contacting the side of the fuel tank. 3. Position the lock ring (2) over the top of the variable speed fuel pump module (3). 4. Position the lock ring remover/installer 9340 (1) into the notches on the outside edge of the lock ring (2). 5. Install a 1/2 inch drive breaker bar (4) into the lock ring remover/installer 9340 (1). 6. Tighten the lock ring (clockwise) until all seven notches have engaged. 7. Install the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank Installation 8. Lower the vehicle. 9. Install the fuel fill cap. 10. Connect the fuel line quick connect fitting to the fuel rail (1)See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3568 11. Connect the 12 volt battery system ground isolation connector (1). 12. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 13. Start the engine and check for leaks at all fuel tank connections. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Pressure Sensor: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set Fuel Tank Pressure Sensor: Customer Interest Fuel System - MIL ON/DTC P1446 Set NUMBER: 08-005-10 GROUP: Electrical DATE: April 01, 2010 SUBJECT: Fuel Tank Pressure Sensor Connector OVERVIEW: This Bulletin involves replacing the fuel tank pressure sensor connector for diagnostic Trouble Code (DTC) P1446 - Fuel Tank Control System Performance - HEV. MODELS: 2009 (HB) Durango 2009 (HG) Aspen SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that DTC P1446 - Fuel Tank Control System Performance - HEV has been set. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN) verify if P1446 - Fuel Tank Control System Performance - HEV is active. If DTC P1446 - Fuel Tank Control System Performance - HEV is active proceed with repair. Check the service history of the vehicle. If the DTC has ever been reported in the past then proceed with the repair. If DTC's are present other then the one listed above record them on the repair order and with the appropriate Diagnostic Procedures available in TechCONNECT repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: 1. Lower the fuel tank as per the directions on tech connect Emissions Control > Evaporative Emissions > Sensor, Fuel Pressure HEV > Removal HEV. 2. Remove convoluted tubing from the wiring harness. 3. Cut the wires going to the sensor connector 2 inches from the connector. 4. Using the standard crimp/solder/heat shrink procedure for wire splicing found in DealerCONNECT > TechCONNECT > Wiring > Wiring Diagram Information > Wire, add new harness extension to vehicle harness. 5. Check the Pressure Sensor for corrosion on the sensor it self, is it corroded? a. No >>> proceed to Step # 6. b. Yes >>> replace the sensor and continue with repairs. 6. Reinstall connector on to the sensor. 7. Wrap convolute with electrical tape. 8. Reinstall Fuel tank into the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Pressure Sensor: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set > Page 3577 9. Perform StarSCAN diagnostics, clear any stored codes. Re-key to confirm P1446 fault is not active. 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set Fuel Tank Pressure Sensor: All Technical Service Bulletins Fuel System - MIL ON/DTC P1446 Set NUMBER: 08-005-10 GROUP: Electrical DATE: April 01, 2010 SUBJECT: Fuel Tank Pressure Sensor Connector OVERVIEW: This Bulletin involves replacing the fuel tank pressure sensor connector for diagnostic Trouble Code (DTC) P1446 - Fuel Tank Control System Performance - HEV. MODELS: 2009 (HB) Durango 2009 (HG) Aspen SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that DTC P1446 - Fuel Tank Control System Performance - HEV has been set. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN) verify if P1446 - Fuel Tank Control System Performance - HEV is active. If DTC P1446 - Fuel Tank Control System Performance - HEV is active proceed with repair. Check the service history of the vehicle. If the DTC has ever been reported in the past then proceed with the repair. If DTC's are present other then the one listed above record them on the repair order and with the appropriate Diagnostic Procedures available in TechCONNECT repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: 1. Lower the fuel tank as per the directions on tech connect Emissions Control > Evaporative Emissions > Sensor, Fuel Pressure HEV > Removal HEV. 2. Remove convoluted tubing from the wiring harness. 3. Cut the wires going to the sensor connector 2 inches from the connector. 4. Using the standard crimp/solder/heat shrink procedure for wire splicing found in DealerCONNECT > TechCONNECT > Wiring > Wiring Diagram Information > Wire, add new harness extension to vehicle harness. 5. Check the Pressure Sensor for corrosion on the sensor it self, is it corroded? a. No >>> proceed to Step # 6. b. Yes >>> replace the sensor and continue with repairs. 6. Reinstall connector on to the sensor. 7. Wrap convolute with electrical tape. 8. Reinstall Fuel tank into the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Pressure Sensor: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set > Page 3583 9. Perform StarSCAN diagnostics, clear any stored codes. Re-key to confirm P1446 fault is not active. 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3588 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3589 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3590 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3591 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3592 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3593 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3594 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3595 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3596 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3597 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3598 Information Bus: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3599 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3600 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3601 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3602 Information Bus: Electrical Diagrams BUS COMMUNICATIONS - Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3603 Bus Communications 8W-18-01 Bus Communications 8W-18-02 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3604 Bus Communications 8W-18-03 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3605 Bus Communications 8W-18-04 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3606 Bus Communications 8W-18-05 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3607 Bus Communications 8W-18-06 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3608 Bus Communications 8W-18-07 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3609 Bus Communications 8W-18-08 (HEV) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3610 Bus Communications 8W-18-09 (HEV) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3611 Bus Communications 8W-18-10 (HEV) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3612 Bus Communications 8W-18-11 (HEV) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3613 Bus Communications 8W-18-12 (HEV) Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Communication - Description Information Bus: Description and Operation Communication - Description DESCRIPTION The primary on-board communication network between the microprocessor-based electronic control modules in this vehicle is the Controller Area Network (CAN) data bus system. However, on vehicles equipped with the optional two-mode Hybrid Electric Vehicle (HEV) technology, Hybrid Local Area Network (H-LAN) data bus and a D-PT data bus are used in addition to the CAN bus. A data bus network minimizes redundant wiring connections and at the same time, reduces wire harness complexity, sensor current loads and controller hardware, by allowing each sensing device to be connected to only one module (also referred to as a node). Each node reads, then broadcasts its sensor data over the bus for use by all other nodes requiring that data. Each node ignores the messages on the bus that it cannot use. The CAN, H-LAN and D-PT busses are each two-wire multiplex systems. Multiplexing is any system that enables the transmission of multiple messages over a single channel or circuit. The CAN bus is used for communication between all vehicle nodes, except on HEV vehicles. In HEV vehicles, the microprocessors of the Traction Power Inverter Module (TPIM), the Transmission Electro Hydraulic Control Module (TEHCM), the Transmission Control Module (TCM), the Battery Pack Control Module (BPCM) and the Accessory Power Module (APM) use the H-LAN bus to communicate with each other and with other electronic modules in the vehicle through a Hybrid Gateway Module (HGM). The the TPIM has a direct D-PT bus connection over which it communicates with the Powertrain Control Module (PCM) (also known as the Engine Control Module/ECM). However, in addition to the CAN bus network, certain nodes may also be equipped with a dedicated Local Interface Network (LIN), Serial Controller Interface (SCI) or a K-Line serial link bus to provide direct communication between that node and certain sensor inputs. There are actually three separate CAN bus systems used in the vehicle. They are designated: the CAN-B, the CAN-C and the diagnostic CAN-C. The CAN-B and CAN-C systems provide on-board communication between all of the nodes that are connected to them. The CAN-C and is the faster of the two systems, providing near real-time communication (500 Kbps), but is less fault tolerant than the CAN-B system. The H-LAN and D-PT busses also communicate at 500 Kbps. The CAN-C is used typically for communications between more critical nodes, while the slower (83.3 Kbps), but more fault tolerant CAN-B system is used for communications between less critical nodes. The CAN-B fault tolerance comes from its ability to revert to a single wire communication mode if there is a fault in the bus wiring. The added speed of the CAN data bus network is many times faster than the previous data bus systems. This added speed facilitates the addition of more electronic control modules or nodes and the incorporation of many new electrical and electronic features in the vehicle. The Diagnostic CAN-C bus is also capable of 500 Kbps communication, and is sometimes informally referred to as the CAN-D system, to differentiate it from the other high speed CAN-C bus. The Diagnostic CAN-C is used exclusively for the transmission of diagnostic information between the Front Control Module (FCM) and a diagnostic scan tool connected to the industry-standard 16-way Data Link Connector (DLC) located beneath the instrument panel on the driver side of the vehicle. All vehicles have a Central Gate way (CGW or FCMCGW) or hub module integral to the FCM that connects to all three CAN buses. This gateway physically and electrically isolates the CAN buses from each other and coordinates the bi-directional transfer of messages between them. Vehicles equipped with the HEV technology also have a separate HGM secured to a bracket on the front of the Transmission Auxiliary Oil Pump (TAOP) module located in the left rear corner of the engine compartment. This separate gateway module isolates the H-LAN bus from the CAN bus and coordinates the bi-directional transfer of messages between the LAN bus and the CAN bus connected to all other nodes in the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Communication - Description > Page 3616 Information Bus: Description and Operation Communication - Operation OPERATION Either the Controller Area Network (CAN) data bus or the hybrid bus system that integrates the Hybrid Local Area Network (H-LAN) data bus with the CAN bus, allows all electronic modules or nodes connected to either bus to share information with each other. Regardless of whether a message originates from a module on the lower speed CAN-B bus or on the higher speed CAN-C, CAN-D, H-LAN or the D-PT bus, the message structure and layout are similar. This allows the Front Control Module/Central Gate way (FCM or FCMCGW) or the separate Hybrid Gateway Module (HGM) to process and transfer messages between the busses. The FCM also stores a Diagnostic Trouble Code (DTC) for certain bus network faults. All modules (also referred to as nodes) transmit and receive messages over one of these buses, either the CAN, GM LAN or D-PT. Data exchange between nodes is achieved by serial transmission of encoded data messages. Each node can both send and receive serial data simultaneously. Each digital bit of a bus message is carried over the bus as a voltage differential between the two bus circuits, when strung together, forms a message. Each node uses arbitration to sort the message priority if two competing messages are attempting to broadcast at the same time. The voltage network used to transmit messages requires biasing and termination. Each module on the CAN bus network provides its own biasing and termination. There are two types of nodes used in the CAN-C, H-LAN or D-PT bus network. A dominant node has a 120 Ohm termination resistance, while a non-dominant (or recessive) node has about a 2500 to 3000 Ohm (2.5 to 3.0 kilo ohm) termination resistance. The dominant nodes on the CAN-C bus are the FCM and the Powertrain Control Module (PCM). The dominant nodes on the CAN Hybrid bus are the Accessory Power Module (APM) integral to the Traction Power Inverter Module (TPIM), the FCM, the Hybrid Gateway Module (HGM) and the PCM. The termination resistance of two dominant nodes is combined in parallel to provide a total of about 60 Ohms. This resistance value may vary by application, depending upon the number of non-dominant nodes on the CAN-C bus. On the CAN-D bus (or Diagnostic CAN-C), all of the 60 Ohm termination resistance is present in the Central Gate way (FCMCGW) or, with the CAN Hybrid bus, in the FCM. NOTE: All measurement of termination resistance is done with the vehicle battery disconnected. NOTE: Termination resistance of a CAN-B node cannot be verified with a Digital Multi-Meter (DMM) or Digital Volt-Ohm Meter (DVOM). The transceiver of each CAN-B node connects to termination resistors internally. When the vehicle battery is disconnected, the internal connections of all CAN-B node transceivers are switched open, disconnecting the termination resistors. Therefore, the total bus resistance measured under these conditions is extremely high or infinite, which does not accurately reflect the actual termination resistance of the CAN-B bus. The communication protocol being used for the CAN data bus is a non-proprietary open standard adopted from the Bosch CAN specification 2.0b. The CAN-C is the faster of the two primary buses in the CAN bus system, providing near real-time communication (500 Kbps). The H-LAN bus uses a GMW3110 protocol. The CAN, H-LAN and D-PT bus nodes are connected in parallel to the two-wire bus using a twisted pair. These wires are wrapped around each other to provide shielding from unwanted electromagnetic induction, thus preventing interference with the relatively low voltage signals being carried through them. The twisted pairs have between 33 and 50 twists per meter (yard). While the CAN bus is operating (active), one of the bus wires carries a higher voltage and is referred to as the CAN High or CAN bus (+) wire, while the other bus wire carries a lower voltage and is referred to as the CAN Low or CAN bus (-) wire. Refer to the CAN Bus Voltages table. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Communication - Description > Page 3617 In order to minimize the potential effects of the Ignition-OFF Draw (IOD), the CAN-B network employs a sleep strategy. However, a network sleep strategy should not be confused with the sleep strategy of the individual nodes on that network, as they may differ. For example: The CAN-C bus network awakes only when the ignition switch is in the ON or START positions; however, the FCM, which is on the CAN-C bus, may still be awake with the ignition switch in the ACCESSORY or UNLOCK positions. The integrated circuitry of an individual node may be capable of processing certain sensor inputs and outputs without the need to utilize network resources. The CAN-B bus network remains active until all nodes on that network are ready for sleep. This is determined by the network using tokens in a manner similar to polling. When the last node that is active on the network is ready for sleep and it has already received a token indicating that all other nodes on the bus are ready for sleep, it broadcasts a bus sleep acknowledgment message that causes the network to sleep. Once the CAN-B bus network is asleep, any node on the bus can awaken it by transmitting a message on the network. The FCM keeps either the CAN-B or the CAN-C bus awake for a timed interval after it receives a diagnostic message for that bus over the diagnostic CAN-C bus. In the CAN system available options are configured into the FCM at the assembly plant, but additional options can be added in the field using the diagnostic scan tool. The configuration settings are stored in non-volatile memory. The FCM also has two 64-bit registers, which track each of the as-built and currently responding nodes on the CAN-B and CAN-C buses. The FCM stores a Diagnostic Trouble Code (DTC) in one of two caches for any detected active or stored faults in the order in which they occur. One cache stores powertrain (P-Code), chassis (C-Code) and body (B-Code) DTCs, while the second cache is dedicated to storing network (U-Code) DTCs. If there are intermittent or active faults in the CAN network, a diagnostic scan tool connected to the Diagnostic CAN-C bus through the 16-way Data Link Connector (DLC), may only be able to communicate with the FCM. To aid in CAN network diagnosis, the FCM provides the CAN-B and CAN-C network status information to the scan tool using certain diagnostic signals. In addition, the transceiver in each node on the CAN-C bus identifies a bus off hardware failure, while the transceiver in each node on the CAN-B bus identifies a general bus hardware failure. The transceivers for some CAN-B nodes also identifies certain failures for both CAN-B bus signal wires. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) Knock Sensor: Locations Knock Sensor 1 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3622 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3623 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3624 Knock Sensor: Locations Knock Sensor 2 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3625 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way Knock Sensor: Diagrams Knock Sensor 2 (3.7L/5.7L) 2 Way Connector (3.7L/5.7L) - (ENGINE) 2 WAY SENSOR-KNOCK 2 (3.7L/5.7L) - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way > Page 3628 Knock Sensor: Diagrams Knock Sensor 1 (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-KNOCK 1 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor - Description Knock Sensor: Description and Operation Knock Sensor - Description DESCRIPTION 3.7L - Two knock sensors (1) are bolted to the cylinder block under the intake manifold. 4.7L - One knock sensor (1) is bolted to the cylinder block under the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor - Description > Page 3631 5.7L - Two knock sensors (1) are bolted to each side of the cylinder block (outside) under each exhaust manifold (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor - Description > Page 3632 Knock Sensor: Description and Operation Knock Sensor - Operation OPERATION When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric crystal which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal 5.7L Two knock sensors (1) are used. Each sensor is bolted to the outside of the cylinder block below the exhaust manifold (3). 1. Raise the vehicle. 2. Disconnect the knock sensor electrical connector (5). 3. Remove the knock sensor mounting bolt (2). NOTE: Note the foam strip on bolt threads. This foam strip is used only to retain the bolts to the sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove the knock sensor (1) from the engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 3635 Knock Sensor: Service and Repair Knock Sensor - Installation 5.7L 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). NOTE: Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt (2). Tighten to 15 +/- 2 ft. lbs. (20 Nm) (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Auto Shut Down Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3639 Main Relay (Computer/Fuel System): Diagrams Connector (IN PDC) RELAY-AUTO SHUT DOWN (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay Description DESCRIPTION The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description > Page 3642 Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay - Operation PCM Output PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Removal REMOVAL The ASD relay is located in the engine compartment within the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal > Page 3645 Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Installation INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Malfunction Indicator Lamp - Description Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp - Description DESCRIPTION A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located in the center of the speedometer, in the area to the left of the speedometer needle hub. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Malfunction Indicator Lamp - Description > Page 3650 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp - Operation OPERATION The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM over the Controller Area Network (CAN) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the MIL for the following reasons: - Bulb Test - Each time the ignition switch turns to the on position the indicator is illuminated for about 15 seconds as a bulb test. The entire bulb test is a function of the PCM. - MIL Lamp-On Message - Each time the cluster receives an electronic MIL lamp-on message from the PCM, the indicator illuminates. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM message. For some DTCs, if a problem does not recur, the PCM sends a lamp-off message automatically. Other DTCs may require that a fault be repaired and the PCM be reset before a lamp-off message is sent. For more information on the PCM, and the DTC set and reset parameters, See: Emission Control Systems/Testing and Inspection. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the PCM for 10 consecutive message cycles, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM. - Self Test - Each time the cluster is put through the self test, the MIL indicator turns on during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the MIL or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. If the CCN turns on the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. Use a diagnostic scan tool for proper diagnosis of the fuel and emissions systems, the PCM, the CCN, the CAN data bus or the electronic communication related to MIL operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3654 Manifold Pressure/Vacuum Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-MAP - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3655 Manifold Pressure/Vacuum Sensor: Description and Operation OPERATION The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal 5.7L 1. Disconnect Map sensor (1) electrical connector. 2. Rotate MAP sensor (1) 1/4 turn counterclockwise for removal. 3. Lift MAP sensor (1) upward. 4. Check condition of sensor o-ring (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 3658 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 5.7L 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring (2) for cuts or tears. 3. Position MAP sensor (1) into manifold. 4. Rotate MAP sensor (1) clockwise for installation. 5. Connect electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3662 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3663 Oil Pressure Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-OIL PRESSURE - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3664 Oil Pressure Sensor: Description and Operation DESCRIPTION The oil pressure sensor uses the following three circuits: - Signal circuit to the PCM - Sensor ground circuit through the PCM - 5 volt reference circuit from the PCM The oil pressure sensor returns a voltage signal back to the PCM with reference to oil pressure. Ground for the sensor is supplied by the PCM. The oil pressure sensor is located on the right side of the engine block. The sensor screws into the engines main oil gallery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Oil Pressure Sensor - Removal Oil Pressure Sensor: Service and Repair Oil Pressure Sensor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the High Voltage Power Down Procedure . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Raise and support the vehicle. 3. Disconnect the oil pressure sensor electrical connector (1). 4. Remove the oil pressure sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Oil Pressure Sensor - Removal > Page 3667 Oil Pressure Sensor: Service and Repair Oil Pressure Sensor - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions NOTE: Apply Mopar(R) Thread Sealant with PTFE to the sensor threads before installing into the engine block. 1. Install the oil pressure sensor (1). 2. Connect the oil pressure sensor electrical connector (1). 3. Lower the vehicle. 4. Perform the High Voltage Power Up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3672 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3673 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3674 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3675 Oxygen Sensor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3676 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3677 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3678 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3679 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3680 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way Oxygen Sensor: Diagrams Oxygen Sensor 1/1 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/1 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way > Page 3683 Oxygen Sensor: Diagrams Oxygen Sensor 1/2 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/2 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way > Page 3684 Oxygen Sensor: Diagrams Oxygen Sensor 2/1 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/1 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way > Page 3685 Oxygen Sensor: Diagrams Oxygen Sensor 2/2 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/2 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3686 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3687 Oxygen Sensor: Description and Operation DESCRIPTION The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors. Federal Emission Packages : Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3688 Oxygen Sensor: Testing and Inspection CHECKING THE OXYGEN SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. OXYGEN SENSOR, WIRING, OR CONNECTORS NOTE: Diagnose and repair any O2 sensor or rationality DTCs before proceeding with this test. NOTE: When performing this procedure as part of another diagnostic process, it may be necessary to repeat this test for all of the oxygen sensors on the vehicle. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 2 2. OXYGEN SENSOR VOLTAGE 1. Start the engine and allow it to reach normal operating temperature. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 2. With a scan tool, monitor all O2 Sensor voltage readings. Is the voltage switching between 2.5 and 3.4 volts for all O2 sensors? Yes - Go to 3 - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 4 3. O2 SENSOR HEATER OPERATION 1. Turn the ignition off. NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0 volts. 2. Turn the ignition on. 3. With a scan tool, actuate the O2 Sensor heater. 4. With the scan tool, monitor O2 Sensor voltage for at least 2 minutes. Does the voltage stay above 4.5 volts? Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3689 Yes - Go to 4 - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Test complete. 4. O2 SENSOR 1. Turn the ignition off. NOTE: Check for contaminants that may cause improper O2 Sensor operation, such as contaminated fuel, unapproved silicone, or evidence of oil or coolant. 2. Disconnect the O2 Sensor harness connector. 3. Turn the ignition on. 4. With a scan tool, monitor the O2 Sensor voltage. NOTE: The voltage should be approximately 5.0 volts with the connector disconnected. 5. Connect a jumper wire between the signal circuit and the return circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from 5.0 volts to 2.5 volts with the jumper wire in place. Is the O2 Sensor voltage displayed on the scan tool as described? Yes - Replace the O2 Sensor. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 5 5. O2 SENSOR SIGNAL CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Signal circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor signal circuit for a short to ground, open circuit, short to voltage, or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 6 6. O2 SENSOR RETURN CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Return circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor return circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3690 No - Go to 7 7. POWERTRAIN CONTROL MODULE (PCM) 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the O2 sensor and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Monitor the scan tool data relative to the components tested in this procedure and wiggle test the wiring and connectors. 5. Look for the data to change or for a DTC to set during the wiggle test. 6. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Replace and program the Powertrain Control Module (PCM). - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal REMOVAL Refer to graphic for typical O2S (oxygen sensor) locations if equipped with four oxygen sensors. Refer to graphic for typical O2S (oxygen sensor) locations if equipped with two oxygen sensors. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow the engine to cool before removing the oxygen sensor. 1. Raise and support vehicle. 2. 4-Sensor System If removing the right-upstream (2/1) sensor, remove the right-front tire/wheel, and then remove the plastic inner fender liner. 3. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on the wire going into sensor. 4. Remove O2S sensor with an oxygen sensor removal and installation tool. 5. Clean threads in exhaust pipe using appropriate tap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3693 Oxygen Sensor: Service and Repair Installation INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor and tighten to 30 ft. lbs. (41 Nm) torque. 2. Connect O2S sensor wire connector. 3. 4-Sensor System: If installing the right-upstream (2/1) sensor, install plastic inner fender liner, and right-front tire/wheel. 4. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Front Control Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Front Control Module > Page 3699 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way Body Control Module: Diagrams Front Control Module (PDC AUX) 49 Way Connector - (PDC AUX) 49 WAY MODULE-FRONT CONTROL - (PDC AUX) 49 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 3702 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 3703 Body Control Module: Diagrams Front Control Module C1 (Headlamp And Dash) 24 Way Connector C1 - (HEADLAMP AND DASH) 24 WAY MODULE-FRONT CONTROL - (HEADLAMP AND DASH) 24 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 3704 Body Control Module: Diagrams Front Control Module C2 (Headlamp And Dash) 12 Way Connector C2 - (HEADLAMP AND DASH) 12 WAY MODULE-FRONT CONTROL - (HEADLAMP AND DASH) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 3705 Body Control Module: Diagrams Hybrid Gateway Module C1 (HEV) (Headlamp And Dash) 24 Way Connector C1 (HEV) - (HEADLAMP AND DASH) 24 WAY MODULE-HYBRID GATEWAY (HEV) - (HEADLAMP AND DASH) 24 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 3706 Body Control Module: Diagrams Hybrid Gateway Module C2 (HEV) (Headlamp And Dash) 12 Way Connector C2 (HEV) - (HEADLAMP AND DASH) 12 WAY MODULE-HYBRID GATEWAY (HEV) - (HEADLAMP AND DASH) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description Body Control Module: Description and Operation Gateway Module - Description DESCRIPTION Vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system have a Hybrid Gateway Module (HGM) (1) that is secured with three screws to the stamped steel Transmission Auxiliary Oil Pump (TAOP) control module mounting bracket located on the left hydro form (frame rail) near the back of the left front wheel housing within the engine compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum HGM housing is the electronic circuitry of the HGM, which includes a microprocessor and an electronic printed circuit board. A stamped metal cover plate (2) is sealed and secured to the HGM housing with four screws to enclose and protect the internal electronic circuitry and components. Two molded plastic electrical connectors (3), one containing 24 terminal pins and the other containing 12 terminal pins, exit the forward facing side of the HGM cover plate and are pointed downward. These terminal pins connect the HGM to the vehicle electrical system through two dedicated take outs and connectors of the headlamp and dash wire harness. The HGM housing has integral mounting flanges on two sides with three mounting holes in each flange. The mounting flange to the left of the connector receptacles is secured to the TAOP control module mounting bracket with two screws, while the flange on the right side is secured to the bracket with only one screw. The HGM cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description > Page 3709 Body Control Module: Description and Operation Front Control Module - Description DESCRIPTION The Front Control Module (FCM) is a micro controller based module located in the left front corner of the engine compartment. The front control module mates to the power distribution center to form the Integrated Power Module (IPM). The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The front control module controls power to some of these vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the CAN bus circuit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description > Page 3710 Body Control Module: Description and Operation Front Control Module - Operation OPERATION As messages are sent over the CAN bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are controlled by the FCM: - Front turn signals - Stop, turn signal and tail lamps - Front and rear hazard warning lamps - Headlamps - Fog Lamps - Daytime running lamps - if equipped - Horn - Windshield and liftgate wiper and washer systems - Transfer case shifting - Trailer tow wiring output - Rear window defroster power and timing - Air conditioning condenser cooling fan The FCM provides the following features for the above function: - It provides a illuminated approach feature that turns the headlamps on when the vehicle is unlocked with the Remote Keyless Entry (RKE) transmitter. - It flashes lamps in response to turn signal, RKE and Vehicle Theft Security System (VTSS) inputs. - It sounds the horn in response to RKE and VTSS inputs. - It turns off the horn in the event of excessively long operation that could otherwise damage the horn. - It turns off the windshield washer motor after 10 seconds of continuous operation to protect the motor. - It minimizes voltage variations to the headlamps to extend bulb life and to equalize the light output from the lamps, which might otherwise differ due to variations in wiring resistance. - If the headlamps are left on, it automatically turns them off after eight minutes to protect the battery from discharge.It monitors battery voltage and turns off non-essential functions such as the fog lamps, rear window defogger, and heated seats if necessary to conserve battery power. - It operates the high-beam headlamps at reduced intensity by pulse-width modulation of the power supply to provide the daytime running lamps. - It provides the variable delay intermittent windshield and liftgate wiper time delay features, and the vehicle speed sensitive windshield wiper delay variation. - It acts as a link between the CAN bus network for critical powertrain and anti-lock brake systems and the network for body and interior modules. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description > Page 3711 Body Control Module: Description and Operation Gateway Module - Operation OPERATION The Hybrid Gateway Module (HGM) provides a communication interface between the electronic control modules (nodes) in the vehicle, as well as with the diagnostic scan tool connected to the Controller Area Network (CAN) data bus system and the nodes connected to the Hybrid Local Area Network (H-LAN) data bus system. The HGM is the central gateway that processes and transfers messages between the different bus systems. In addition, the HGM is Local Interface Network (LIN) bus compatible. It receives a direct input over the LIN bus from a humidity sensor secured to the inside rear view mirror mount on the inside of the windshield glass, which it then transmits over the CAN data bus to other electronic modules in the vehicle. The microprocessor-based HGM also provides input and output circuitry that responds to both digital and analog inputs and provides electronically controlled higher current load outputs through lower current relay drivers. The HGM uses On-Board Diagnostics (OBD). If the HGM detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) that can be retrieved with a diagnostic scan tool through the 16-way data link connector located on the driver side lower edge of the instrument panel. The HGM connects directly to a fused battery current input and to ground, so that it remains capable of operating, regardless of the ignition switch position. The hardwired inputs and outputs for the HGM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the HGM, the electronic controls or communication between other modules and devices that provide features of the Hybrid Electric Vehicle (HEV) control system. The most reliable, efficient and accurate means to diagnose the HGM, the electronic controls and communication related to HGM operation, requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Front Control Module (FCM) Intermittent Condition Test Body Control Module: Testing and Inspection Front Control Module (FCM) Intermittent Condition Test INTERMITTENT CONDITION For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. INTERMITTENT CONDITION NOTE: The conditions that set the DTC are not present at this time. The following list may help in identifying the intermittent condition. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 1. Perform any Technical Service Bulletins (TSBs) that may apply. 2. Review the scan tool Freeze Frame information. If possible, try to duplicate the conditions under which the DTC set. 3. Turn the ignition off. 4. Visually inspect the related wire harness. Wiggle the related wire harness and look for an interrupted signal on the affected circuit. Disconnect all the related harness connectors. Look for any chafed, pierced, pinched, partially broken wires and broken, bent, pushed out, or corroded terminals. 5. Perform a voltage drop test on the related circuits between the suspected inoperative component and the Anti-Lock Brake Module, Front Control Module, or Totally Integrated Power Module, which every applies to the circuits in questions. 6. Inspect and clean all Powertrain Control Module (PCM), APS, engine, and chassis grounds that are related to the most current DTC. 7. If numerous trouble codes were set, use a wire schematic and look for any common ground or supply circuits 8. For any Relay DTCs, actuate the Relay with the scan tool and wiggle the related wire harness to try to interrupt the actuation. 9. Use the scan tool to perform a System Test if one applies to failing component. 10. A co-pilot, data recorder, and/or lab scope should be used to help diagnose intermittent conditions. Were any problems found during the above inspections? Yes - Perform the necessary repairs. - Perform the APS VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/APS Verification Test. No - Test Complete. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Front Control Module (FCM) Intermittent Condition Test > Page 3714 Body Control Module: Testing and Inspection Wireless Control Module (WCM) Intermittent Condition Test WIRELESS CONTROL MODULE (WCM) INTERMITTENT TEST For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. RECORD AND ERASE ALL WCM DIAGNOSTIC TROUBLE CODES (DTCS) Using a scan tool, record and erase all DTCs from the WCM. Monitor any active codes as you work through the following steps. - Review the code monitor and set conditions for any DTCs that are stored and attempt to reproduce the conditions listed. - Wiggle the wiring harness and connectors of the related circuit, sensor or component. - Turn the ignition off. Search for any Technical Service Bulletins (TSBs) that may apply. Was the source of the customer complaint found or did any DTCs appear and stay active? Yes - Make the appropriate repairs and perform the WIRELESS CONTROL MODULE (WCM) VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Wireless Control Module (WCM) Verification Test or select the correct DTC procedure. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. No - Go To 2 2. ATTEMPT TO REPRODUCE THE CONDITION In the event the customer complaint cannot be duplicated due to an intermittent condition in the theft/security system, the following may aid in attempting to reproduce the condition. - Using the wiring diagram/schematic as a guide, inspect the wiring and connectors related to the stored code or component in question. - Look for chafed, pierced, pinched, or partially broken wires and broken, bent, pushed out, spread, corroded, or contaminated terminals. - If the customer concern was related to a specific fobik, ensure the fobik in question is used while attempting reproduce the condition. - Reconnect any disconnected components and harness connectors and ensure they are properly seated. - If numerous trouble codes were set, use a schematic and inspect any common ground or supply circuits. Was the source of the intermittent condition located? Yes - Make the appropriate repairs and perform the WIRELESS CONTROL MODULE (WCM) VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Wireless Control Module (WCM) Verification Test No - The problem cannot be found at this time. If repeated intermittent failures are encountered that cannot be reproduced and the condition has prompted multiple customer visits to the dealership, document any findings on the repair order. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Front Control Module (FCM) Intermittent Condition Test > Page 3715 Body Control Module: Testing and Inspection Wireless Control Module (WCM) Pre-Diagnostic Procedure WIRELESS CONTROL MODULE (WCM) PRE-DIAGNOSTIC PROCEDURE Before attempting to repair any theft or security system, technicians should be familiar with and fully understand the system operation. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Description and Operation/Vehicle Theft Security System - Description. The following should be used as a checklist to be completed in its entirety prior to referencing specific Theft and Security Diagnostic Procedures. FOLLOW THE BASIC OUTLINE IN THE SIX-STEP TROUBLESHOOTING PROCEDURE - Verification of complaint - Verification of any related symptoms - Symptom analysis - Problem isolation - Repair of isolated problem - Verification of proper operation TAKE INTO ACCOUNT CURRENT VEHICLE CONDITION, REPAIR HISTORY, AND TECHNICAL SERVICE BULLETINS (TSBs) - Verify there are no outward signs of vehicle damage that could impact the proper operation of the theft or security system. Check for aftermarket vehicle accessories that may have been installed improperly or could interfere with the system - Check the vehicle repair history for repairs that may relate to the current condition. - Perform a check of current Technical Service Bulletins (TSB) for the system related to the customer concern. If a TSB applies, follow the procedure outlined in the TSB. DIAGNOSE ONLY THOSE FAILURES THAT ARE ACTIVE AND CAN BE REPRODUCED - Check the control module central to the subsystem that is exhibiting the condition for active Diagnostic Trouble Codes (DTCs). - For an intermittent failure that is not current at the time of vehicle inspection, refer to the WIRELESS CONTROL MODULE INTERMITTENT TEST See: Wireless Control Module (WCM) Intermittent Condition Test and document the event on the repair order. ADDRESS ACTIVE DTCS IN THE CORRECT ORDER - Low/High Voltage and Serial Data Loss of Communication Codes - Module Internal Failure and Configuration Mismatch Codes - Circuit specific DTC failures As a general rule, for any theft/security system control module that exhibits more than one active DTC, address the codes in the order indicated; should the malfunction still be present after conducting this Pre-diagnostic Procedure, technicians should continue to the appropriate DTC procedure or symptom diagnostic. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal Body Control Module: Service and Repair Gateway Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. A technician trained in proper Hybrid Electric Vehicle (HEV) service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. Unlatch and remove the Power Distribution Center (PDC) from the PDC mounting bracket on the left hydro form (frame rail) over the left front wheel house in the engine compartment. Move the PDC forward far enough to access the Hybrid Gateway Module (HGM) (1). 3. Remove the three screws (2) that secure the HGM to the Transmission Auxiliary Oil Pump (TAOP) control module mounting bracket (3) that is secured to the left hydro form near the back of the left front wheel house. 4. Disconnect the two headlamp and dash wire harness connectors (4) from the HGM connector receptacles located on the forward facing side of the module. 5. Remove the HGM from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal > Page 3718 Body Control Module: Service and Repair Gateway Module - Installation INSTALLATION 1. Position the Hybrid Gateway Module (HGM) (1) near the Transmission Auxiliary Oil Pump (TAOP) control module mounting bracket (3) that is secured to the left hydro form (frame rail) near the back of the left front wheel house in the engine compartment. 2. Reconnect the two headlamp and dash wire harness connectors (4) to the HGM connector receptacles located on the forward facing side of the module. 3. Position the HGM to the TAOP control module mounting bracket. 4. Install and tighten the three screws (2) that secure the HGM to the mounting bracket. Tighten the screws securely. 5. Reinstall the Power Distribution Center (PDC) onto the PDC mounting bracket on the left hydro form over the left front wheel house in the engine compartment. Be certain that each of the PDC latches is fully engaged with the mounting bracket. 6. Reconnect the battery negative cable. A technician trained in proper Hybrid Electric Vehicle (HEV) service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal > Page 3719 Body Control Module: Service and Repair Front Control Module - Removal REMOVAL 1. Disconnect the positive and negative battery cables from the battery. 2. Partially remove the Integrated Power Module (IPM) from the engine compartment. 3. Remove the front control module retaining screws. 4. Pull the front control module straight from the IPM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal > Page 3720 Body Control Module: Service and Repair Front Control Module - Installation INSTALLATION 1. Press the Front Control Module (FCM) onto the Integrated Power Module (IPM). 2. Install the mounting fasteners. 3. Install the IPM. 4. Connect the positive and negative battery cables. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 3724 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way Engine Control Module: Diagrams Powertrain Control Module C1 38 Way Connector C1 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3727 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3728 Engine Control Module: Diagrams Powertrain Control Module C2 38 Way Connector C2 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3729 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3730 Engine Control Module: Diagrams Powertrain Control Module C3 38 Way Connector C3 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3731 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3732 Engine Control Module: Diagrams Powertrain Control Module C4 38 Way Connector C4 - (ENGINE) 38 WAY MODULE-POWERTRAIN CONTROL - (ENGINE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module C1 38 Way > Page 3733 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description Engine Control Module: Description and Operation Powertrain Control Module - Description PCM POWERTRAIN CONTROL MODULE (PCM) The PCM (2) is attached to the right-front inner fender (1) located in the engine compartment. Modes of Operation MODES OF OPERATION As input signals to the Powertrain Control Module (PCM) change, the PCM adjusts its response to the output devices. The PCM will operate in two different modes: Open Loop and Closed Loop. During Open Loop modes, the PCM receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensors is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensors input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: - Ignition switch ON - Engine start-up (crank) - Engine warm-up - Idle - Cruise - Acceleration - Deceleration - Wide open throttle (WOT) - Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: - The PCM pre-positions the idle air control (IAC) motor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3736 - The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. - The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. - Intake manifold air temperature sensor input is monitored. - Throttle position sensor (TPS) is monitored. - The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds. - The fuel pump is energized through the fuel pump relay by the PCM. The fuel pump will operate for approximately three seconds unless the engine is operating or the starter motor is engaged. - The O2S sensor heater element is energized via the ASD relay. The O2S sensor input is not used by the PCM to calibrate air-fuel ratio during this mode of operation. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The PCM receives inputs from: - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Starter motor relay - Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warm-up, the PCM receives inputs from: - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Based on these inputs the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. - The PCM operates the A/C compressor clutch through the clutch relay. This is done if A/C has been selected by the vehicle operator and requested by the A/C thermostat. - When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation. IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3737 - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Battery voltage - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by increasing and decreasing spark advance. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the PCM receives inputs from: - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Oxygen (O2S) sensors Based on these inputs, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. - The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. - The PCM adjusts ignition timing by turning the ground path to the coil on and off. - The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. ACCELERATION MODE This is an Open Loop mode. The PCM recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the PCM receives the following inputs. - Air conditioning select signal (if equipped) - Air conditioning request signal (if equipped) - Battery voltage - Engine coolant temperature sensor - Crankshaft position sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal - Park/neutral switch (gear indicator signal-auto. trans. only) - Vehicle speed sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3738 If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM will ignore the oxygen sensor input signal. The PCM will enter a fuel cut-off strategy in which it will not supply a ground to the injectors. If a hard deceleration does not exist, the PCM will determine the proper injector pulse width and continue injection. Based on the above inputs, the PCM will adjust engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the PCM receives the following inputs. - Battery voltage - Crankshaft position sensor - Engine coolant temperature sensor - Intake manifold air temperature sensor - Manifold absolute pressure (MAP) sensor - Throttle position sensor (TPS) - Camshaft position sensor signal During wide open throttle conditions, the following occurs: - Voltage is applied to the fuel injectors with the ASD relay via the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. - The PCM adjusts ignition timing by turning the ground path to the coil on and off. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay. 5V Power Supplies 5 VOLT SUPPLIES Two different Powertrain Control Module (PCM) five volt supply circuits are used; primary and secondary. Ignition Circuit Sense IGNITION CIRCUIT SENSE This circuit ties the ignition switch to the Powertrain Control Module (PCM). Battery voltage is supplied to the PCM through the ignition switch when the ignition is in the Run or Start position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Power Grounds POWER GROUNDS The Powertrain Control Module (PCM) has 2 main grounds. Both of these grounds are referred to as power grounds. All of the high-current, noisy, electrical devices are connected to these grounds as well as all of the sensor returns. The sensor return comes into the sensor return circuit, passes through noise suppression, and is then connected to the power ground. The power ground is used to control ground circuits for the following PCM loads: - Generator field winding - Fuel injectors - Ignition coil(s) - Certain relays/solenoids - Certain sensors Sensor Return SENSOR RETURN Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3739 The Sensor Return circuits are internal to the Powertrain Control Module (PCM). Sensor Return provides a low-noise ground reference for all engine control system sensors. For more information, See: . Signal Ground SIGNAL GROUND Signal ground provides a low noise ground to the data link connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3740 Engine Control Module: Description and Operation Powertrain Control Module - Operation PCM POWERTRAIN CONTROL MODULE (PCM) The PCM is a pre-programmed, microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, certain transmission features, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. The PCM receives input signals from various switches and sensors. Based on these inputs, the PCM regulates various engine and vehicle operations through different system components. These components are referred to as Powertrain Control Module (PCM) Outputs. The sensors and switches that provide inputs to the PCM are considered Powertrain Control Module (PCM) Inputs. The PCM adjusts ignition timing based upon inputs it receives from sensors that react to: engine rpm, manifold absolute pressure, engine coolant temperature, throttle position, transmission gear selection (automatic transmission), vehicle speed and the brake switch. The PCM adjusts idle speed based on inputs it receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine coolant temperature and from inputs it receives from the air conditioning clutch switch and brake switch. Based on inputs that it receives, the PCM adjusts ignition coil dwell. The PCM also adjusts the generator charge rate through control of the generator field and provides speed control operation. NOTE: PCM Inputs: - Accelerator pedal position sensor (if equipped) - A/C request (if equipped with factory A/C) - A/C select (if equipped with factory A/C) - Auto shutdown (ASD) sense - Battery temperature - Battery voltage - Brake switch - CAN bus (+) circuits - CAN bus (-) circuits - Camshaft position sensor signal - Clutch Interlock Switch (if equipped) - Crankshaft position sensor - Data link connection for diagnostic scan tool - EGR position sensor (if equipped) - Engine coolant temperature sensor - Fuel level - Generator (battery voltage) output - Ignition circuit sense (ignition switch in on/off/crank/run position) - Intake manifold air temperature sensor - Knock sensor(s) (if equipped) - Leak detection pump (switch) sense (if equipped) - Manifold absolute pressure (MAP) sensor - Oil pressure sensor - Output shaft speed sensor - Overdrive/override switch - Oxygen sensors - Park/neutral switch (auto. trans. only) - Power ground - Power steering pressure switch (if equipped) - Sensor return - Signal ground - Speed control multiplexed single wire input - Throttle position sensor - Transmission governor pressure sensor - Transmission output speed sensor - Transmission temperature sensor - Vehicle speed inputs from ABS or RWAL system Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module - Description > Page 3741 NOTE: PCM Outputs: - A/C clutch relay - Auto shutdown (ASD) relay - CAN bus (+/-) circuits for: speedometer, voltmeter, fuel gauge, oil pressure gauge/lamp, engine temp. gauge and speed control warn. lamp - Data link connection for diagnostic scan tool - Double start override (if equipped) - EGR valve control solenoid (if equipped) - Electronic throttle control - EVAP canister purge solenoid - Five volt sensor supply (primary) - Five volt sensor supply (secondary) - Fuel injectors - Fuel pump relay - Generator field driver (-) - Generator field driver (+) - Generator lamp (if equipped) - Idle air control (IAC) motor - Ignition coil(s) - CAN bus circuits - Leak detection pump (if equipped) - Malfunction indicator lamp (Check engine lamp). Driven through CAN bus circuits. - Overdrive indicator lamp (if equipped) - Radiator cooling fan (if equipped) - Speed control vacuum solenoid - Speed control vent solenoid - Starter relay - Tachometer (if equipped). Driven through CAN bus circuits. - Transmission convertor clutch circuit - Transmission 3-4 shift solenoid - Transmission relay - Transmission temperature lamp (if equipped) - Transmission variable force solenoid 5V Power Supplies 5 VOLT SUPPLIES Primary 5-volt supply: - supplies the required 5 volt power source to the Crankshaft Position (CKP) sensor. - supplies the required 5 volt power source to the Camshaft Position (CMP) sensor. - supplies a reference voltage for the Manifold Absolute Pressure (MAP) sensor. - supplies a reference voltage for the Throttle Position Sensor (TPS) sensor. Secondary 5-volt supply: - supplies the required 5 volt power source to the oil pressure sensor. - supplies the required 5 volt power source for the Vehicle Speed Sensor (VSS) (if equipped). - supplies the 5 volt power source to the transmission pressure sensor (if equipped with an RE automatic transmission). Ignition Circuit Sense IGNITION CIRCUIT SENSE The ignition circuit sense input tells the PCM the ignition switch has energized the ignition circuit. Battery voltage is also supplied to the PCM through the ignition switch when the ignition is in the RUN or START position. This is referred to as the "ignition sense" circuit and is used to "wake up" the PCM. Voltage on the ignition input can be as low as 6 volts and the PCM will still function. Voltage is supplied to this circuit to power the PCM's 8-volt regulator and to allow the PCM to perform fuel, ignition and emissions control functions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3742 Engine Control Module: Testing and Inspection CHECKING THE PCM POWER AND GROUND CIRCUITS For a complete wiring diagram refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. PCM WIRING OR CONNECTORS 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and each connector at the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. No - Go To 2 2. CHECKING THE PCM GROUND CIRCUITS 1. Turn the ignition off. CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to 12 volts, check the PCM ground circuits. 3. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go To 3. No - Repair the PCM ground circuit(s) for an open circuit or high resistance. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3743 3. CHECKING THE PCM FUSED IGNITION CIRCUITS CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 1. Turn the ignition on. 2. Using a 12 volt test light connected to ground, check the PCM Fused Ignition circuits. 3. Check each circuit with the ignition on, engine running position, and during cranking. 4. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated and bright? Yes - Go To 4. No - Repair the open or short to ground in the PCM Fused Ignition circuits. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. 4. CHECKING THE PCM FUSED B+ CIRCUITS 1. Turn the ignition off. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3744 CAUTION: Do not probe the PCM harness connectors. Probing the PCM harness connectors will damage the PCM terminals resulting in poor terminal to pin connection. Install PCM Pinout Box 8815 to perform diagnosis. 2. Using a 12 volt test light connected to Ground, check the PCM Fused B+ circuits. 3. Wiggle test each circuit during the test to check for an intermittent open in the circuit. NOTE: The test light should be illuminated and bright with the ignition on and not illuminated with the ignition off. Compare the brightness to that of a direct connection to the battery. Is the test light illuminated as described above? Yes - Test complete. No - Repair the open or short to ground in the PCM Fused B+ circuit(s) for as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Resolver Learn STANDARD PROCEDURE - RESOLVER LEARN RESOLVER OFFSET LEARN TRIGGER EVT AHS-T TRANSMISSION The Resolver Offset Learn Trigger Procedure requires the use of a scan tool. This program allows the electronic variable transmission (EVT) AHS-T to re-calibrate itself. This will provide the proper transmission operation. The resolver offset learn procedure should be performed if any of the following procedures are performed: - Transmission Assembly Replacement - Transmission Electronic Hydraulic Control Module (TEHCM) Replacement - Flashing the TCM - Electric Motors Replacement - Valve Body Replacement or Recondition To perform the Resolver Offset Learn Trigger Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The shift lever position must stay in PARK until prompted to shift. - The calculated oil temperature must be above 15° C (60° F) and below 93° C (200° F) TCM Quick Learn QUICK LEARN TCM QUICK LEARN RFE and RLE The quick learn procedure requires the use of a scan tool. This program allows the electronic transmission system to re-calibrate itself. This will provide the proper transmission operation. The quick learn procedure should be performed if any of the following procedures are performed: - Transmission Assembly Replacement - Transmission Control Module Replacement - Solenoid Pack Replacement - Clutch Plate and/or Seal Replacement - Valve Body Replacement or Recondition To perform the Quick Learn Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The throttle angle (TPS) must be less than 3 degrees - The shift lever position must stay in PARK until prompted to shift to overdrive - The shift lever position must stay in overdrive after the Shift to Overdrive prompt until the scan tool indicates the procedure is complete - The calculated oil temperature must be above 15° C (60° F) and below 93° C (200° F) TCM Drive Learn DRIVE LEARN RFE and RLE When a transmission is repaired and a Quick Learn procedure has been performed on the Transmission Control Module (TCM), the following Drive Learn procedure can be performed to fine tune any shifts which are particularly objectionable. NOTE: It is not necessary to perform the complete Drive Learn procedure every time the TCM is Quick Learned. Perform only the portions which target the objectionable shift. LEARN A SMOOTH 1ST NEUTRAL TO DRIVE SHIFT Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3747 Perform this procedure only if the complaint is for a delayed or harsh shift the first time the transmission is put into gear after the vehicle is allowed to set with the engine not running for at least 10 minutes. Use the following steps to have the TCM learn the 1st N-D UD CVI. NOTE: The transmission oil temperature must be between 27-43° C (80-110° F). 1. Start the engine only when the engine and ignition have been off for at least ten (10) minutes. 2. With the vehicle at a stop and the service brake applied, record the 1st N-D UD CVI while performing a Neutral to Drive shift. The 1st N-D UD CVI accounts for air entrapment in the UD clutch that may occur after the engine has been off for a period of time. 3. Repeat 1 and 2 until the recorded 1st N-D UD CVI value stabilizes. NOTE: It is important that this procedure be performed when the transmission temperature is between 27-43° C (80-110° F). If this procedure takes too long to complete fully for the allowed transmission oil temperature, the vehicle may be returned to the customer with an explanation that the shift will improve daily during normal vehicle usage. The TCM also learns at higher oil temperatures, but these values (line pressure correction values) are not available for viewing on the scan tool. LEARN A SMOOTH NEUTRAL TO DRIVE GARAGE SHIFT Perform this procedure if the complaint is for a delayed or harsh shift when the transmission is put into gear after the vehicle has had its first shift. Use the following steps to have the TCM learn the Norm N-D UD CVI. NOTE: The transmission oil temperature must be between 27-43° C (80-110° F) to learn the UD CVI. Additional learning occurs at temperatures as low as -18° C (0° F) and as high as 93° C (200° F). This procedure may be performed at any temperature that experiences poor shift quality. Although the UD CVI may not change, shift quality should improve. 1. Start the vehicle engine and shift to drive. 2. Move the vehicle forward to a speed of at least 16 km/h (10 MPH) and come to a stop. This ensures no air is present in the UD hydraulic circuit. 3. Perform repeated N-D shifts at a stop while pausing in Neutral for at least 2-3 seconds and monitor Norm N-D UD CVI volume until the value stabilizes. The value will change during the N-D shift. This is normal since the UD value is different for the N-D shift then the normal value shown which is used for 4-3 coastdown and kick downs. Perform repeated shifts in this temperature range until the Norm N-D UD CVI value stabilizes and the N-D shifts become smooth. LEARN THE 1ST 2-3 SHIFT AFTER A RESTART OR SHIFT TO REVERSE Use the following steps to have the TCM learn the 1st 2-3 shift OD CVI. NOTE: The transmission oil temperature must be above 27° C (80° F). 1. With the vehicle engine running, select reverse gear for over 2 seconds. 2. Shift the transmission to Drive and accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform a 2-3 shift while noting the 1st 2-3 OD CVI. 3. Repeat 1 and 2 until the 1st 2-3 upshift becomes smooth and the 1st 2-3 OD CVI stabilizes. LEARN A SMOOTH 2-3 AND 3-4 UPSHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the OD and 4C CVI's. 1. Accelerate the vehicle from a stop at a steady 15 degree throttle opening and perform multiple 1-2, 2-3, and 3-4 upshifts. The 2nd 2-3 shift following a restart or shift to reverse will be shown during the shift as a value between the 1st 2-3 OD CVI and the normal OD CVI. Updates to the normal OD CVI will occur after the 2nd shift into 3rd gear, following a restart or shift to reverse. 2. Repeat 1 until the 2-3 and 3-4 shifts become smooth and the OD and 4C CVI become stable. LEARN A SMOOTH 4-3 COASTDOWN AND PART THROTTLE 4-3 KICKDOWN NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the UD shift volume. 1. At a vehicle speed between 64-97 km/h (40-60 MPH), perform repeated 4-3 kickdown shifts. 2. Repeat 1 until the UD volume becomes somewhat stable and the shift becomes smooth. LEARN A SMOOTH 1-2 UPSHIFT AND 3-2 KICKDOWN Use the following steps to have the TCM learn the 2C shift volume. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3748 NOTE: The transmission oil temperature must be above 43° C (110° F). 1. With a vehicle speed below 48 km/h (30 MPH) and the transmission in 3rd gear, perform multiple 3-2 kick downs. 2. Repeat 1 until the 3-2 kick downs become smooth and the 2C CVI becomes stable. LEARN A SMOOTH MANUAL 2-1 PULLDOWN SHIFT AS WELL AS A NEUTRAL TO REVERSE SHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the LR volume. 1. With the vehicle speed around 40-48 km/h (25-30 MPH) in Manual 2nd, perform manual pulldowns to Low or 1st gear at closed throttle. 2. Repeat 1 until the LR CVI becomes stable and the manual 2-1 becomes smooth. LEARN A SMOOTH NEUTRAL TO REVERSE SHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). 1. With the vehicle at a stop, perform Neutral to Reverse shifts until the shift is smooth. An unlearned Neutral to Reverse shift may be harsh or exhibit a double bump. 2. If any of the shifts are still not smooth after the clutch volume stabilizes, an internal transmission problem may be present. LEARN A SMOOTH 4-5 UPSHIFT NOTE: The transmission oil temperature must be above 43° C (110° F). Use the following steps to have the TCM learn the Alt 2C CVI. 1. Accelerate the vehicle through 88 km/h (55 mph) at a steady 10-15 degree throttle opening and perform multiple 4-5 upshifts. 2. Repeat 1 until the 4-5 shift become smooth and the Alt 2C CVI become stable. There is a separate 2C volume used and learned for 4-5 shifts, 2CA. It is independent of the 2C CVI learned on 3-2 kick downs. PCM/ECM Reprogramming PCM/ECM REPROGRAMMING - GAS PCM / TCM FLASH REPROGRAMING This procedure will need to be done when one or more of the following situations are true: 1. A vehicle's Powertrain control module (PCM) has been replaced. 2. A diagnostic trouble code (DTC) is set "P1602 - PCM Not Programmed." 3. An updated calibration or software release is available for either the PCM or TCM ECUs. This procedure assumes that the StarSCAN(R) and StarMOBILE(R) devices are configured to your dealership's network with either a wired or wireless connection. The StarSCAN(R) and StarMOBILE(R) must also be running at the latest operating system and software release level. For more help on how to network your StarSCAN(R) or StarMOBILE(R) reference the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation' under the Download Center. Table of contents 1. SECTION 1 - PCM / TCM FLASH PROCEDURE SECTION 1 - PCM / TCM FLASH PROCEDURE 2. REQUIRED TOOLS/EQUIPMENT REQUIRED TOOLS/EQUIPMENT: 3. TECH TIPS and INFORMATIONTECH TIPS and INFORMATION: 4. PARTS REQUIRED PARTS REQUIRED SECTION 1 - PCM / TCM FLASH PROCEDURE If using StarSCAN(R) or StarMOBILE(R) Desktop Client. Go to REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client If using StarMOBILE(R) Stand-alone Diagnostic Mode. Go To REPAIR PROCEDURE - Using StarMOBILE(R) Stand-alone Diagnostic Mode REPAIR PROCEDURE - Using StarSCAN(R) or StarMOBILE(R) Desktop Client Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3749 NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 1. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 2. Connect the StarSCAN(R) or StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 3. Power on the StarSCAN(R) or StarMOBILE(R). If the StarMOBILE(R) is being used, launch the StarMOBILE(R) Desktop Client and connect to the appropriate StarMOBILE(R) device. 4. Retrieve the old ECU part number. From the tool's Home screen, a. Select "ECU View" b. Select "PCM" c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the Flash PCM screen for later reference. 5. Program the ECU as follows: a. Using the StarSCAN(R) / StarMOBILE(R) at the Home screen, select "ECU View" b. Select "PCM" c. Select "More Options" d. Select "ECU Flash" e. Select "Browse for New File" and follow the on screen instructions. f. Highlight the appropriate calibration based on the part number recorded in Step 4e, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. g. Select "Download to Scantool" h. Once the download is complete, select "Close" and then "Back" i. Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. j. When the PCM update is complete, select "OK" k. Verify that the part number at the top of the Flash PCM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 6. Continue to SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 7. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See Section 3 SECTION 3 - AUTHORIZED MODIFICATION LABEL for details). REPAIR PROCEDURE - Using StarMOBILE(R) Stand-alone Diagnostic Mode NOTE: StarMOBILE(R) Stand-alone Mode is an efficient way to flash ECUs without having direct access to a network connection. It involves first copying the flash file to the StarMOBILE(R) device which DOES require a network connection. Once the file has been copied to the StarMOBILE(R) device, it can be used in a Stand-alone mode to flash the ECU WITHOUT a network connection. NOTE: StarMOBILE(R) does not need to be connected to a vehicle when retrieving a flash file for Stand-alone Mode. 1. Power on the StarMOBILE(R). Launch the StarMOBILE(R) Desktop Client and connect to the tool. 2. At the Home screen, select "ECU View" a. Select "PCM" b. Select "More Options" c. Select "ECU Flash" d. Select "Browse for New File" and follow the on screen instructions. e. Highlight the appropriate calibration based on the current ECU part number, or by using Year/Model/Engine and appropriate emissions selection for the vehicle being worked on. NOTE: If you are not connected to the vehicle, you may also search for flash files by selecting the "Flash Download" button from the Home screen. 3. From the Flash File List, select the appropriate calibration for the PCM and select "Download to Client" 4. Once the download is complete, hit "OK" and then "Manage Files" Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3750 5. In the Manage Files screen, highlight the downloaded flash file and select "Copy to SM Device". A green check mark should now appear in the On SM Device column. 6. Exit the StarMOBILE(R) Desktop Client application. 7. Open the hood of the vehicle and install a battery charger. Verify that the charging rate provides a continuous charge of 13.2 - 13.5 volts. 8. Connect the StarMOBILE(R) to the vehicle data link connector located under the steering column and turn the ignition key to the "RUN" position. 9. On the StarMOBILE(R) device, select "Enter Stand-alone Diagnostic Mode" (use the right function key). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3751 NOTE: If a StarMOBILE(R) Desktop Client is still associated with the device, you will receive the following error: "Your StarMOBILE(R) device is currently locked by a pc named 'xxxxxxxx' on your network. To remove the lock, close its Desktop Client or reboot this device". 10. Program the ECU as follows: a. Select "ECU View" b. Select "PCM" c. Select "Flash ECU" d. Record the ECU part number at the very top of the screen for later reference. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3752 e. Highlight the flash file that you want to use. Hit "SELECT" and then "OK". Follow the on screen instructions. f. Once the flash is complete, verify that the part number at the top of the Flash PCM screen has updated to the new part number. NOTE: If this flash process is interrupted or aborted, the flash should be restarted. 11. Continue to Section 2SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES to complete the process if the ECU has been replaced. 12. Type the necessary information on the "Authorized Modification Label" (p/n 04275086AB) and attach near the VECI label (See Section 3 SECTION 3 - AUTHORIZED MODIFICATION LABEL for details). SECTION 2 - ADDITIONAL PCM / TCM REPLACEMENT PROCEDURES Find the PCM/TCM Type for the vehicle, read and write down the steps, and then go to the step by step instructions for additional information on how to perform these procedures. STEP-BY-STEP INSTRUCTIONS If a NGC3 or NGC4 PCM was replaced, perform the following additional steps and/or routines: 1. PCM Replaced - if WCM equipped 2. Learn ETC - if ETC equipped 3. Check PCM Odometer 4. Check PCM VIN - if NOT WCM equipped 5. Quicklearn - if EATX equipped If a GPEC PCM was replaced, perform the following additional steps and/or routines: 1. If the vehicle is equipped with a CVT, ensure that the TCM has the latest software calibration available (if the vehicle is not equipped with a CVT, skip to Step 3). 2. PCM Replaced - if WCM equipped Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3753 3. Learn ETC 4. Check PCM Odometer 5. Check PCM VIN - if NOT WCM equipped 6. TCM Quicklearn - if EATX equipped If a CVT TCM was replaced, perform the following additional steps and/or routines: 1. Initialize CVT If an EGS TCM was replaced, perform the following additional steps and/or routines: 1. Initialize EGS STEP-BY-STEP INSTRUCTIONS Check PCM Odometer From the "Home" screen, select "ECU View". - Select "PCM" - Select "Misc. Functions" - Select "Check PCM Odometer" and follow the on screen instructions. - When complete, select "Finish". Check PCM VIN From the "Home" screen, select "ECU View" - Select "PCM" - Select "Misc. Functions" - Select "Check PCM VIN" and follow the on screen instructions. - When complete, select "Finish" Initialize CVT From the "Home" screen, select "ECU View" - Select "TCM" - Select "Misc. Functions" - Select "Initialize CVT" and follow the on screen instructions. - When complete, select "Finish" Initialize EGS From the "Home" screen, select "ECU View" - Select "TCM" - Select "Misc. Functions" - Select "Initialize EGS" and follow the on screen instructions. - When complete, select "Finish" Learn ETC From the "Home" screen, select "ECU View" - Select "PCM" - Select "Misc. Functions" - Select "Learn ETC" and follow the on screen instructions. - When complete, select "Finish" PCM Replaced The vehicle pin (Personal Identification Number) will be required to complete the routine. This information may be obtained in three ways: 1. The original selling invoice 2. Dealer CONNECT > Parts > Key Codes Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3754 3. Contacting the District Manager. From the "Home" screen, select "ECU View" - Select "WCM" - Select "Misc. Functions" - Select "PCM Replaced" and follow the on screen instructions. - When complete, select "Finish" Quicklearn From the "Home" screen, select "ECU View" - Select "PCM" - Select "Misc. Functions" - Select "Quicklearn" and follow the on screen instructions. - When complete, select "Finish" Update CVT TCM From the "Home" screen: - Select "ECU View" - Select "TCM" - Select "More Options" - Select "ECU Flash" - Select "Browse for New File" and follow the on screen instructions. - Highlight the appropriate calibration. - Select "Download to Scantool" - Once the download is complete, select "Close" and then "Back" - Highlight the listed calibration, select "Update Controller" and follow the on screen instructions. - When the TCM update is complete, select "OK" - Verify that the part number at the top of the "Flash TCM" screen has updated to the latest level. SECTION 3 - AUTHORIZED MODIFICATION LABEL NOTE: The following step is required by law when reprogramming a PCM and/or TCM. Type the necessary information on the "Authorized Modification Label" and attach near the VECI label. 1. Powertrain Control / Transmission Control Module Part Numbers (Insert P/Ns) Used 2. Change Authority: TSB XX--XX 3. Dealer Code: XXXXX 4. Date: XX-XX-XX REQUIRED TOOLS/EQUIPMENT: TECH TIPS and INFORMATION: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3755 1. StarMOBILE(R) Stand-alone Diagnostic Mode is an efficient way to flash ECUs without having direct access to a network connection. It involves first copying the flash file to the StarMOBILE(R) device which DOES require a network connection. Once the file has been copied to the StarMOBILE(R) device, it can be used in a Stand-alone mode to flash the ECU WITHOUT a network connection. 2. To use the StarMOBILE(R) in Pass-Through Mode requires that your StarMOBILE(R) is connected to the dealerships network via a wired or wireless connection. For more information on how to use the StarMOBILE in Pass-Through Mode see the StarMOBILE(R) training tutorials available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Training Aids' link under the 'Training Aids' link. 3. StarMOBILE(R) does not need to be connected to a vehicle when retrieving a flash file for Stand-alone Mode. 4. Extreme care must be taken when programming a calibration into a generic PCM. Do not randomly select a calibration. Once a calibration is selected and programmed, the controller cannot be reprogrammed to a different calibration. The ECU can only be reprogrammed to a more recent version of that calibration. 5. If the flash process is interrupted or aborted, the flash should be restarted. 6. Due to the PCM / TCM programming procedure, a DTC may be set in other ECUs within the vehicle. Some DTCs may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 7. When replacing a GPEC PCM for a vehicle that is equipped with a CVT, it is extremely important that the PCM and TCM both have the latest software calibrations. 8. Do not allow the battery charger to time out or the charging rate to climb above 13.5 volts during the flash process. 9. The StarSCAN(R) and StarMOBILE(R) diagnostic tools fully support Internet connectivity and must be configured for your dealership's network. For help on setting up your StarSCAN(R) / StarMOBILE(R) for the dealership's network, refer to the StarSCAN(R) / StarMOBILE(R) Quick Start Networking Guide available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation' under the download center. 10. The operating software in the StarSCAN(R) and StarMOBILE(R) must be programmed with the latest software release level. The software level is visible in the blue header at the top of the StarSCAN(R) and StarMOBILE(R) Desktop Client screens. For instructions on how to update your scan tool, refer to the StarSCAN(R) / StarMOBILE(R) Software Update guide available on 'Dealer CONNECT > Service > StarSCAN(R) and StarMOBILE(R) Tools > Online Documentation' under the download center. PARTS REQUIRED SKREEM Programming SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3756 lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: - PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3757 - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3758 Engine Control Module: Removal and Replacement Powertrain Control Module - Removal REMOVAL CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. The PCM (2) is attached to the right-front inner fender (1) located in the engine compartment. To avoid possible voltage spike damage to the PCM, ignition key must be off, and negative battery cable must be disconnected before unplugging PCM connectors. 1. Disconnect and isolate the negative battery cable. 2. Remove both wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal. 3. Remove wiper cowl (two screws, four pins). 4. Remove wiper cowl support (three bolts). 5. Remove air intake tube (four nuts). 6. Carefully unplug the four 38-way connectors (3) from PCM. 7. Remove three PCM mounting bolts (4), and remove PCM from vehicle. Powertrain Control Module - Installation INSTALLATION CAUTION: Certain ABS systems rely on having the Powertrain Control Module (PCM) broadcast the Vehicle Identification Number (VIN) over the bus network. To prevent problems of DTCs and other items related to the VIN broadcast, it is recommend that you disconnect the ABS CAB (controller) temporarily when replacing the PCM. Once the PCM is replaced, write the VIN to the PCM using the scan tool. This is done from the engine main menu. Arrow over to the second page to "1. Miscellaneous". Select "Check VIN" from the choices. Make sure it has the correct VIN entered before continuing. When the VIN is complete, turn off the ignition key and reconnect the ABS module connector. This will prevent the setting of DTCs and other items associated with the lack of a VIN detected when you turn the key ON after replacing the PCM. CAUTION: Use the scan tool to reprogram the new PCM with the vehicles original identification number (VIN) and the vehicles original mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3759 1. Position PCM (2) to vehicle. 2. Install three PCM mounting bolts (4). 3. Tighten bolts to 3-5 Nm (30-40 in. lbs.). 4. Check pin connectors in the PCM. Also check the four 38-way connectors (3) for corrosion or damage. Repair as necessary. 5. Install the four 38-way connectors (3) to PCM. 6. Install air intake tube (four nuts). 7. Install wiper cowl support (three bolts). 8. Install wiper cowl (two screws, four pins). 9. Install both wiper arms. 10. Connect negative battery cable. 11. Use the diagnostic scan tool to reprogram new PCM with vehicles original Identification Number (VIN) and original vehicle mileage. If this step is not done, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Auto Shut Down Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3763 Main Relay (Computer/Fuel System): Diagrams Connector (IN PDC) RELAY-AUTO SHUT DOWN (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay Description DESCRIPTION The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description > Page 3766 Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay - Operation PCM Output PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Removal REMOVAL The ASD relay is located in the engine compartment within the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal > Page 3769 Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Installation INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Locations > Page 3774 Accelerator Pedal Position Sensor: Diagrams Connector - (HEADLAMP AND DASH) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (HEADLAMP AND DASH) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (6) is attached to the accelerator pedal assembly (4) under the instrument panel. The APPS is used only with the 5.7L V-8 engine. The APPS is part of the pedal assembly and is a non-serviceable part and the pedal assembly has to be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 3777 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) is a linear potentiometer. It provides the Powertrain Control Module (PCM) with a DC voltage signal proportional to the angle, or position of the accelerator pedal. The APPS signal is translated (along with other sensors) to place the throttle plate (within the throttle body) to a pre-determined position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor > Page 3782 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3783 Camshaft Position Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-CAMSHAFT POSITION - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description 5.7L The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 3786 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation 5.7L The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.7L The Camshaft Position Sensor (CMP) (3) is located on right side of timing gear/chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from timing gear/chain cover. 4. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 3789 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in timing gear/chain cover. 2. Install sensor (2) into timing gear/chain cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing gear/chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 Nm (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Coolant Temperature Sensor/Switch (For Computer): Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3793 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3794 Coolant Temperature Sensor/Switch (For Computer): Diagrams Connector - (ENGINE) 2 WAY SENSOR-ENGINE COOLANT TEMPERATURE - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3798 Crankshaft Position Sensor: Diagrams Connector (5.7L) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (5.7L) - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description 5.7L The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 3801 Crankshaft Position Sensor: Description and Operation Operation 5.7L Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On the 5.7L V-8 engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 5.7L 1. Raise vehicle. 2. Disconnect CKP electrical connector (2) at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 3804 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking and twisting action. CAUTION: Before tightening the CKP sensor mounting bolt, be sure the sensor is completely flush to the cylinder block. If the CKP sensor is not flush, damage to the sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3808 Fuel Level Sensor: Diagrams Connector - (CHASSIS) 4 WAY MODULE-FUEL PUMP - (CHASSIS) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description Fuel Level Sensor: Description and Operation Fuel Pump Module - Description DESCRIPTION The fuel pump module assembly (4) is located on the top of the fuel tank (2). The module assembly (5) contains the following components: - An internal fuel filter - A separate fuel pick-up, or inlet filter (3) - A fuel pressure regulator (4) - An electric fuel pump (2) - A lock ring to retain pump module to tank - A soft gasket between tank flange and module - A fuel gauge sending unit (fuel level sensor) (1) - Fuel line connection (6) If the fuel gauge sending unit, electrical fuel pump, primary inlet filter, fuel filter or fuel pressure regulator require service, the fuel pump module must be replaced. Electric Fuel Pump The electric fuel pump is located inside of the fuel pump module. A 12 volt, permanent magnet, electric motor powers the fuel pump. The electric fuel pump is not a separate, serviceable component. Fuel Filters Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3811 Two fuel filters are used. One is located at the bottom of the fuel pump module. The other is located inside the module. A separate frame mounted fuel filter is not used with any engine. Both fuel filters are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator The fuel pressure regulator is located within fuel pump module. Fuel Gauge Sending Unit (Fuel level sensor) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation > Fuel Pump Module - Description > Page 3812 Fuel Level Sensor: Description and Operation Variable Speed Fuel Pump Module (HEV) Description DESCRIPTION - HEV The variable speed fuel pump module (5) is located on the top of the fuel tank and contains the following: - Internal fuel filter - Separate fuel pick-up, or inlet filter (3) - Fuel pressure regulator (4) - Variable speed fuel pump (2) - Lock ring to retain the pump module to the tank - O-ring gasket between the tank flange and pump module - Fuel gauge sending unit (fuel level sensor) (1) - Fuel line connection (6) If the fuel gauge sending unit (fuel level sensor), variable speed fuel pump, primary inlet filter, fuel filter or fuel pressure regulator require service, the variable speed fuel pump module must be replaced as a unit. Variable Speed Fuel Pump The Hybrid Electric Vehicle (HEV) uses a variable speed fuel pump module, an additional fuel pump speed relay and a resistor to provide low speed capability to the fuel pump system. A diagnostic monitor circuit allows the PCM to verify operation of the following two circuits: - Fuel pump relay control circuit which results in closing the fuel pump relay allowing current to flow through the fuel pump speed relay for high speed fuel pump operation. - Fuel pump speed relay control circuit which results in closing the fuel pump relay and fuel pump speed relay allowing current to flow through the resistor for low speed fuel pump operation. The variable speed fuel pump is not a separate, serviceable component. Fuel Filters Two fuel filters are used. One is located at the bottom of the fuel pump module. The other is located inside the module. A separate frame mounted fuel filter is not used. Both fuel filters are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator The fuel pressure regulator is located within the fuel pump module and is not a separate, serviceable component. Fuel Gauge Sending Unit (fuel level sensor) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, a float arm, and a variable resistor track (card). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Level Sensor: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: The fuel system is under a constant pressure, even with the engine off. Before servicing the fuel pump module, the fuel system pressure must be released. 1. Perform the fuel system pressure release procedure See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect and isolate the negative battery cable. 3. Drain and remove the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank Removal 4. Note the rotational position of the module before attempting removal. An indexing arrow is located on top of the module for this purpose. 5. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 6. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 7. Rotate the breaker bar counterclockwise to remove the lock ring. 8. Remove the lock ring. The module will spring up slightly when the lock ring is removed. 9. Remove the module from the fuel tank. Be careful not to bend the float arm during removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3815 Fuel Level Sensor: Service and Repair Fuel Pump Module - Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position the fuel pump module into the opening of the fuel tank. 2. Rotate the module until the embossed alignment arrow points to the center alignment mark. This step must be performed to prevent the float from contacting the side of the fuel tank. Also be sure the fuel fitting on top of the pump module is pointed to the left side of the vehicle. 3. Position the lock ring (5) over the top of the fuel pump module. 4. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 5. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 6. Tighten the lock ring (clockwise) until all seven notches have engaged. 7. Install the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation 8. Lower the vehicle. 9. Connect the fuel line quick connect fitting to the fuel rail (1)See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair 10. Connect the negative battery cable. 11. Install the fuel fill cap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3816 Fuel Level Sensor: Service and Repair Variable Speed Fuel Pump Module (HEV) - Removal REMOVAL - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: The fuel system is under a constant pressure, even with the engine off. Before servicing the fuel pump module, the fuel system pressure must be released. 1. Perform the fuel system pressure release procedure See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 3. Disconnect the 12 volt battery system ground isolation connector (1). 4. Drain the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Procedures for Draining Fuel Tank HEV procedure. 5. Remove the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal NOTE: Prior to removing the variable speed fuel pump module, use compressed air to remove any accumulated dirt and debris from around fuel tank opening. CAUTION: An indexing arrow is located on top of the variable speed fuel pump module to clock it's position into the fuel tank, note it's location for reassembly. 6. Position the lock ring remover/installer 9340 (1) into the notches on the outside edge of the lock ring (2). 7. Install a 1/2 inch drive breaker bar (4) into the lock ring remover/installer 9340 (1). NOTE: The variable speed fuel pump module will spring up slightly when the lock ring is removed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3817 8. Rotate the breaker bar counterclockwise and remove the lock ring. CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 9. Remove the variable speed fuel pump module (3) from the fuel tank. Be careful not to bend the float arm during removal. 10. Remove and discard the rubber O-ring seal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3818 Fuel Level Sensor: Service and Repair Variable Speed Fuel Pump Module (HEV) - Installation INSTALLATION - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions CAUTION: Whenever the fuel pump module is serviced, the rubber O-ring seal must be replaced. 1. Using a new rubber O-ring seal, position the variable speed fuel pump module into the opening of the fuel tank. 2. Rotate the variable speed fuel pump module until the embossed alignment arrow points to the center alignment mark as noted during disassembly. This step must be performed to prevent the float from contacting the side of the fuel tank. 3. Position the lock ring (2) over the top of the variable speed fuel pump module (3). 4. Position the lock ring remover/installer 9340 (1) into the notches on the outside edge of the lock ring (2). 5. Install a 1/2 inch drive breaker bar (4) into the lock ring remover/installer 9340 (1). 6. Tighten the lock ring (clockwise) until all seven notches have engaged. 7. Install the fuel tank See: Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank Installation 8. Lower the vehicle. 9. Install the fuel fill cap. 10. Connect the fuel line quick connect fitting to the fuel rail (1)See: Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 3819 11. Connect the 12 volt battery system ground isolation connector (1). 12. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 13. Start the engine and check for leaks at all fuel tank connections. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set Fuel Tank Pressure Sensor: Customer Interest Fuel System - MIL ON/DTC P1446 Set NUMBER: 08-005-10 GROUP: Electrical DATE: April 01, 2010 SUBJECT: Fuel Tank Pressure Sensor Connector OVERVIEW: This Bulletin involves replacing the fuel tank pressure sensor connector for diagnostic Trouble Code (DTC) P1446 - Fuel Tank Control System Performance - HEV. MODELS: 2009 (HB) Durango 2009 (HG) Aspen SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that DTC P1446 - Fuel Tank Control System Performance - HEV has been set. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN) verify if P1446 - Fuel Tank Control System Performance - HEV is active. If DTC P1446 - Fuel Tank Control System Performance - HEV is active proceed with repair. Check the service history of the vehicle. If the DTC has ever been reported in the past then proceed with the repair. If DTC's are present other then the one listed above record them on the repair order and with the appropriate Diagnostic Procedures available in TechCONNECT repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: 1. Lower the fuel tank as per the directions on tech connect Emissions Control > Evaporative Emissions > Sensor, Fuel Pressure HEV > Removal HEV. 2. Remove convoluted tubing from the wiring harness. 3. Cut the wires going to the sensor connector 2 inches from the connector. 4. Using the standard crimp/solder/heat shrink procedure for wire splicing found in DealerCONNECT > TechCONNECT > Wiring > Wiring Diagram Information > Wire, add new harness extension to vehicle harness. 5. Check the Pressure Sensor for corrosion on the sensor it self, is it corroded? a. No >>> proceed to Step # 6. b. Yes >>> replace the sensor and continue with repairs. 6. Reinstall connector on to the sensor. 7. Wrap convolute with electrical tape. 8. Reinstall Fuel tank into the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set > Page 3828 9. Perform StarSCAN diagnostics, clear any stored codes. Re-key to confirm P1446 fault is not active. 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set Fuel Tank Pressure Sensor: All Technical Service Bulletins Fuel System - MIL ON/DTC P1446 Set NUMBER: 08-005-10 GROUP: Electrical DATE: April 01, 2010 SUBJECT: Fuel Tank Pressure Sensor Connector OVERVIEW: This Bulletin involves replacing the fuel tank pressure sensor connector for diagnostic Trouble Code (DTC) P1446 - Fuel Tank Control System Performance - HEV. MODELS: 2009 (HB) Durango 2009 (HG) Aspen SYMPTOM/CONDITION: The customers may experience a MIL illumination. Upon further investigation the Technician may find that DTC P1446 - Fuel Tank Control System Performance - HEV has been set. DIAGNOSIS: Using a Scan Tool (wiTECH or StarSCAN) verify if P1446 - Fuel Tank Control System Performance - HEV is active. If DTC P1446 - Fuel Tank Control System Performance - HEV is active proceed with repair. Check the service history of the vehicle. If the DTC has ever been reported in the past then proceed with the repair. If DTC's are present other then the one listed above record them on the repair order and with the appropriate Diagnostic Procedures available in TechCONNECT repair as necessary before proceeding further with this bulletin. PARTS REQUIRED: REPAIR PROCEDURE: 1. Lower the fuel tank as per the directions on tech connect Emissions Control > Evaporative Emissions > Sensor, Fuel Pressure HEV > Removal HEV. 2. Remove convoluted tubing from the wiring harness. 3. Cut the wires going to the sensor connector 2 inches from the connector. 4. Using the standard crimp/solder/heat shrink procedure for wire splicing found in DealerCONNECT > TechCONNECT > Wiring > Wiring Diagram Information > Wire, add new harness extension to vehicle harness. 5. Check the Pressure Sensor for corrosion on the sensor it self, is it corroded? a. No >>> proceed to Step # 6. b. Yes >>> replace the sensor and continue with repairs. 6. Reinstall connector on to the sensor. 7. Wrap convolute with electrical tape. 8. Reinstall Fuel tank into the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 08-005-10 > Apr > 10 > Fuel System - MIL ON/DTC P1446 Set > Page 3834 9. Perform StarSCAN diagnostics, clear any stored codes. Re-key to confirm P1446 fault is not active. 10. Return vehicle to customer. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Pressure Sensor: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up Control Module HVAC: All Technical Service Bulletins A/C - Does Not Cool Sufficiently/Evaporator Ices Up NUMBER: 24-010-08 GROUP: Air Conditioning DATE: December 19, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.04 OR HIGHER. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: FLASH: Evaporator Freeze Up In A/C Equipped Vehicles OVERVIEW: This Bulletin involves reprogramming the Automatic Temperature Control module with new software. MODELS: 2009 (HB) Durango (HEV Only) 2009 (HG) Aspen(HEV Only) NOTE: This bulletin applies to vehicles equipped with HEV engine (sales code EZE) and Automatic Temperature Control (ATC) ATC (sales code HAF). SYMPTOM/CONDITION: Some customers may experience an intermittent condition where air flow from the HVAC vents is warmer than desired while driving with the HVAC system on. This may be due to evaporator freeze up. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) using the appropriate Diagnostic Procedures available in TechCONNECT, verify all ATC systems are functioning as designed. If DTC's are present record them on a repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is experienced or described by the customer, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 9.04 level software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Pressure Sensor: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up > Page 3840 "DealerCONNECT > Service> StarSCAN(R) and StarMOBILE(R) tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old HVAC part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the HVAC in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash HVAC" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash HVAC" screen has updated to the new part number. NOTE: Due to the HVAC programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 7. Verify proper performance of HVAC system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Pressure Sensor: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up > Page 3841 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Pressure Sensor: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up > Page 3847 "DealerCONNECT > Service> StarSCAN(R) and StarMOBILE(R) tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old HVAC part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the HVAC in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash HVAC" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash HVAC" screen has updated to the new part number. NOTE: Due to the HVAC programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 7. Verify proper performance of HVAC system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Tank Pressure Sensor: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up > Page 3848 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Locations > Page 3852 Intake Air Temperature Sensor: Diagrams Connector HEV - (ENGINE) 2 WAY SENSOR-INTAKE AIR TEMPERATURE HEV - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor - Description Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Description DESCRIPTION The 2-wire Intake Manifold Air Temperature (IAT) sensor is installed in the intake manifold with the sensor element extending into the air stream. The IAT sensor is a two-wire Negative Thermal Coefficient (NTC) sensor. Meaning, as intake manifold temperature increases, resistance (voltage) in the sensor decreases. As temperature decreases, resistance (voltage) in the sensor increases. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation > Intake Air Temperature Sensor - Description > Page 3855 Intake Air Temperature Sensor: Description and Operation Intake Air Temperature Sensor Operation OPERATION The IAT sensor provides an input voltage to the Powertrain Control Module (PCM) indicating the density of the air entering the intake manifold based upon intake manifold temperature. At key-on, a 5-volt power circuit is supplied to the sensor from the PCM. The sensor is grounded at the PCM through a low-noise, sensor-return circuit. The PCM uses this input to calculate the following: - Injector pulse-width - Adjustment of spark timing (to help prevent spark knock with high intake manifold air-charge temperatures) The resistance values of the IAT sensor is the same as for the Engine Coolant Temperature (ECT) sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal Intake Air Temperature Sensor: Service and Repair Removal 5.7L The intake manifold air temperature (IAT) sensor is installed into the front of the intake manifold air box plenum (1). 1. Disconnect electrical connector (2) from IAT sensor. 2. Clean dirt from intake manifold at sensor base. 3. Gently lift on small plastic release tab (3) and rotate sensor about 1/4 turn counterclockwise for removal. 4. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair > Removal > Page 3858 Intake Air Temperature Sensor: Service and Repair Installation 5.7L 1. Check condition of sensor O-ring. 2. Clean sensor mounting hole in intake manifold (1). 3. Position sensor (2) into intake manifold and rotate clockwise until past release tab. 4. Install electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) Knock Sensor: Locations Knock Sensor 1 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3863 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3864 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3865 Knock Sensor: Locations Knock Sensor 2 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 3866 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way Knock Sensor: Diagrams Knock Sensor 2 (3.7L/5.7L) 2 Way Connector (3.7L/5.7L) - (ENGINE) 2 WAY SENSOR-KNOCK 2 (3.7L/5.7L) - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way > Page 3869 Knock Sensor: Diagrams Knock Sensor 1 (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-KNOCK 1 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Description Knock Sensor: Description and Operation Knock Sensor - Description DESCRIPTION 3.7L - Two knock sensors (1) are bolted to the cylinder block under the intake manifold. 4.7L - One knock sensor (1) is bolted to the cylinder block under the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Description > Page 3872 5.7L - Two knock sensors (1) are bolted to each side of the cylinder block (outside) under each exhaust manifold (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation > Knock Sensor Description > Page 3873 Knock Sensor: Description and Operation Knock Sensor - Operation OPERATION When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric crystal which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor Removal Knock Sensor: Service and Repair Knock Sensor - Removal 5.7L Two knock sensors (1) are used. Each sensor is bolted to the outside of the cylinder block below the exhaust manifold (3). 1. Raise the vehicle. 2. Disconnect the knock sensor electrical connector (5). 3. Remove the knock sensor mounting bolt (2). NOTE: Note the foam strip on bolt threads. This foam strip is used only to retain the bolts to the sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove the knock sensor (1) from the engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor Removal > Page 3876 Knock Sensor: Service and Repair Knock Sensor - Installation 5.7L 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). NOTE: Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt (2). Tighten to 15 +/- 2 ft. lbs. (20 Nm) (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3880 Manifold Pressure/Vacuum Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-MAP - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3881 Manifold Pressure/Vacuum Sensor: Description and Operation OPERATION The MAP sensor is used as an input to the Powertrain Control Module (PCM). It contains a silicon based sensing unit to provide data on the manifold vacuum that draws the air/fuel mixture into the combustion chamber. The PCM requires this information to determine injector pulse width and spark advance. When manifold absolute pressure (MAP) equals Barometric pressure, the pulse width will be at maximum. A 5 volt reference is supplied from the PCM and returns a voltage signal to the PCM that reflects manifold pressure. The zero pressure reading is 0.5V and full scale is 4.5V. For a pressure swing of 0-15 psi, the voltage changes 4.0V. To operate the sensor, it is supplied a regulated 4.8 to 5.1 volts. Ground is provided through the low-noise, sensor return circuit at the PCM. The MAP sensor input is the number one contributor to fuel injector pulse width. The most important function of the MAP sensor is to determine barometric pressure. The PCM needs to know if the vehicle is at sea level or at a higher altitude, because the air density changes with altitude. It will also help to correct for varying barometric pressure. Barometric pressure and altitude have a direct inverse correlation; as altitude goes up, barometric goes down. At key-on, the PCM powers up and looks at MAP voltage, and based upon the voltage it sees, it knows the current barometric pressure (relative to altitude). Once the engine starts, the PCM looks at the voltage again, continuously every 12 milliseconds, and compares the current voltage to what it was at key-on. The difference between current voltage and what it was at key-on, is manifold vacuum. During key-on (engine not running) the sensor reads (updates) barometric pressure. A normal range can be obtained by monitoring a known good sensor. As the altitude increases, the air becomes thinner (less oxygen). If a vehicle is started and driven to a very different altitude than where it was at key-on, the barometric pressure needs to be updated. Any time the PCM sees Wide Open Throttle (WOT), based upon Throttle Position Sensor (TPS) angle and RPM, it will update barometric pressure in the MAP memory cell. With periodic updates, the PCM can make its calculations more effectively. The PCM uses the MAP sensor input to aid in calculating the following: - Manifold pressure - Barometric pressure - Engine load - Injector pulse-width - Spark-advance programs - Shift-point strategies (certain automatic transmissions only) - Idle speed - Decel fuel shutoff The MAP sensor signal is provided from a single piezoresistive element located in the center of a diaphragm. The element and diaphragm are both made of silicone. As manifold pressure changes, the diaphragm moves causing the element to deflect, which stresses the silicone. When silicone is exposed to stress, its resistance changes. As manifold vacuum increases, the MAP sensor input voltage decreases proportionally. The sensor also contains electronics that condition the signal and provide temperature compensation. The PCM recognizes a decrease in manifold pressure by monitoring a decrease in voltage from the reading stored in the barometric pressure memory cell. The MAP sensor is a linear sensor; meaning as pressure changes, voltage changes proportionately. The range of voltage output from the sensor is usually between 4.6 volts at sea level to as low as 0.3 volts at 26 in. of Hg. Barometric pressure is the pressure exerted by the atmosphere upon an object. At sea level on a standard day, no storm, barometric pressure is approximately 29.92 in Hg. For every 100 feet of altitude, barometric pressure drops 0.10 in. Hg. If a storm goes through, it can change barometric pressure from what should be present for that altitude. You should know what the average pressure and corresponding barometric pressure is for your area. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal Manifold Pressure/Vacuum Sensor: Service and Repair Removal 5.7L 1. Disconnect Map sensor (1) electrical connector. 2. Rotate MAP sensor (1) 1/4 turn counterclockwise for removal. 3. Lift MAP sensor (1) upward. 4. Check condition of sensor o-ring (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Service and Repair > Removal > Page 3884 Manifold Pressure/Vacuum Sensor: Service and Repair Installation 5.7L 1. Clean MAP sensor mounting hole at intake manifold. 2. Check MAP sensor O-ring (2) for cuts or tears. 3. Position MAP sensor (1) into manifold. 4. Rotate MAP sensor (1) clockwise for installation. 5. Connect electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations Oil Pressure Sensor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3888 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3889 Oil Pressure Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-OIL PRESSURE - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Locations > Page 3890 Oil Pressure Sensor: Description and Operation DESCRIPTION The oil pressure sensor uses the following three circuits: - Signal circuit to the PCM - Sensor ground circuit through the PCM - 5 volt reference circuit from the PCM The oil pressure sensor returns a voltage signal back to the PCM with reference to oil pressure. Ground for the sensor is supplied by the PCM. The oil pressure sensor is located on the right side of the engine block. The sensor screws into the engines main oil gallery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Oil Pressure Sensor - Removal Oil Pressure Sensor: Service and Repair Oil Pressure Sensor - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the High Voltage Power Down Procedure . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Raise and support the vehicle. 3. Disconnect the oil pressure sensor electrical connector (1). 4. Remove the oil pressure sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair > Oil Pressure Sensor - Removal > Page 3893 Oil Pressure Sensor: Service and Repair Oil Pressure Sensor - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions NOTE: Apply Mopar(R) Thread Sealant with PTFE to the sensor threads before installing into the engine block. 1. Install the oil pressure sensor (1). 2. Connect the oil pressure sensor electrical connector (1). 3. Lower the vehicle. 4. Perform the High Voltage Power Up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3898 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3899 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3900 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3901 Oxygen Sensor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3902 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3903 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3904 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3905 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Sensor - Oxygen 1/1 (4.7L) > Page 3906 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way Oxygen Sensor: Diagrams Oxygen Sensor 1/1 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/1 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way > Page 3909 Oxygen Sensor: Diagrams Oxygen Sensor 1/2 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 1/2 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way > Page 3910 Oxygen Sensor: Diagrams Oxygen Sensor 2/1 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/1 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Oxygen Sensor 1/1 (HEV) (Engine) 4 Way > Page 3911 Oxygen Sensor: Diagrams Oxygen Sensor 2/2 (HEV) (Engine) 4 Way Connector (HEV) - (ENGINE) 4 WAY SENSOR-OXYGEN 2/2 (HEV) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3912 Oxygen Sensor: Application and ID - Cylinder bank number one is the bank that contains number one cylinder. See: Ignition System/Firing Order Cylinder #1 on left side. Cylinder #1 on right side. - The first oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/1. - The second oxygen sensor in cylinder bank # 1 is numbered O2 Sensor 1/2. - A third oxygen sensor in cylinder bank # 1 would be numbered O2 Sensor 1/3. - The first oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 2/1. - The second oxygen sensor in cylinder bank # 2 is numbered O2 Sensor 1/1. - If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream HO2S. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3913 Oxygen Sensor: Description and Operation DESCRIPTION The Oxygen Sensors (O2S) are attached to, and protrude into the vehicle exhaust system. Depending on the engine or emission package, the vehicle may use a total of either 2 or 4 sensors. Federal Emission Packages : Two sensors are used: upstream (referred to as 1/1) and downstream (referred to as 1/2). With this emission package, the upstream sensor (1/1) is located just before the main catalytic convertor. The downstream sensor (1/2) is located just after the main catalytic convertor. California Emission Packages: On this emissions package, 4 sensors are used: 2 upstream (referred to as 1/1 and 2/1) and 2 downstream (referred to as 1/2 and 2/2). With this emission package, the right upstream sensor (2/1) is located in the right exhaust downpipe just before the mini-catalytic convertor. The left upstream sensor (1/1) is located in the left exhaust downpipe just before the mini-catalytic convertor. The right downstream sensor (2/2) is located in the right exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. The left downstream sensor (1/2) is located in the left exhaust downpipe just after the mini-catalytic convertor, and before the main catalytic convertor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3914 Oxygen Sensor: Testing and Inspection CHECKING THE OXYGEN SENSOR OPERATION For a complete wiring diagram refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. OXYGEN SENSOR, WIRING, OR CONNECTORS NOTE: Diagnose and repair any O2 sensor or rationality DTCs before proceeding with this test. NOTE: When performing this procedure as part of another diagnostic process, it may be necessary to repeat this test for all of the oxygen sensors on the vehicle. 1. Turn the ignition off. 2. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the Oxygen sensor and the PCM. 3. Look for any chafed, pierced, pinched, or partially broken wires. 4. Look for broken, bent, pushed out or corroded terminals. 5. Turn the ignition on. 6. Monitor the scan tool data relative to the sensor and wiggle test the wiring and connectors. 7. Look for the data to change or for a DTC to set during the wiggle test. If necessary, check each sensor circuit for high resistance or a shorted condition. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 2 2. OXYGEN SENSOR VOLTAGE 1. Start the engine and allow it to reach normal operating temperature. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 2. With a scan tool, monitor all O2 Sensor voltage readings. Is the voltage switching between 2.5 and 3.4 volts for all O2 sensors? Yes - Go to 3 - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 4 3. O2 SENSOR HEATER OPERATION 1. Turn the ignition off. NOTE: Wait a minimum of 10 minutes to allow the O2 Sensor to cool down before continuing the test. Allow the O2 Sensor voltage to stabilize at 5.0 volts. 2. Turn the ignition on. 3. With a scan tool, actuate the O2 Sensor heater. 4. With the scan tool, monitor O2 Sensor voltage for at least 2 minutes. Does the voltage stay above 4.5 volts? Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3915 Yes - Go to 4 - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Test complete. 4. O2 SENSOR 1. Turn the ignition off. NOTE: Check for contaminants that may cause improper O2 Sensor operation, such as contaminated fuel, unapproved silicone, or evidence of oil or coolant. 2. Disconnect the O2 Sensor harness connector. 3. Turn the ignition on. 4. With a scan tool, monitor the O2 Sensor voltage. NOTE: The voltage should be approximately 5.0 volts with the connector disconnected. 5. Connect a jumper wire between the signal circuit and the return circuit in the O2 Sensor harness connector. NOTE: The voltage should drop from 5.0 volts to 2.5 volts with the jumper wire in place. Is the O2 Sensor voltage displayed on the scan tool as described? Yes - Replace the O2 Sensor. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 5 5. O2 SENSOR SIGNAL CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Signal circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor signal circuit for a short to ground, open circuit, short to voltage, or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go to 6 6. O2 SENSOR RETURN CIRCUIT 1. Using the wiring diagram/schematic as a guide, inspect the O2 Sensor Return circuit and connectors between the O2 sensor and the PCM. 2. Check the O2 Sensor return circuit for a short to ground, open circuit, short to voltage or high resistance. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3916 No - Go to 7 7. POWERTRAIN CONTROL MODULE (PCM) 1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the O2 sensor and the PCM. 2. Look for any chafed, pierced, pinched, or partially broken wires. 3. Look for broken, bent, pushed out or corroded terminals. 4. Monitor the scan tool data relative to the components tested in this procedure and wiggle test the wiring and connectors. 5. Look for the data to change or for a DTC to set during the wiggle test. 6. Search for any Technical Service Bulletins that may apply. Were any problems found? Yes - Repair as necessary. - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Replace and program the Powertrain Control Module (PCM). - Perform the POWERTRAIN VERIFICATION TEST. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal Oxygen Sensor: Service and Repair Removal REMOVAL Refer to graphic for typical O2S (oxygen sensor) locations if equipped with four oxygen sensors. Refer to graphic for typical O2S (oxygen sensor) locations if equipped with two oxygen sensors. CAUTION: Never apply any type of grease to the oxygen sensor electrical connector, or attempt any soldering of the sensor wiring harness. WARNING: The exhaust manifold, exhaust pipes and catalytic converter become very hot during engine operation. Allow the engine to cool before removing the oxygen sensor. 1. Raise and support vehicle. 2. 4-Sensor System If removing the right-upstream (2/1) sensor, remove the right-front tire/wheel, and then remove the plastic inner fender liner. 3. Disconnect wire connector from O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on the wire going into sensor. 4. Remove O2S sensor with an oxygen sensor removal and installation tool. 5. Clean threads in exhaust pipe using appropriate tap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Removal > Page 3919 Oxygen Sensor: Service and Repair Installation INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to threads of a new oxygen sensor. 1. Install O2S sensor and tighten to 30 ft. lbs. (41 Nm) torque. 2. Connect O2S sensor wire connector. 3. 4-Sensor System: If installing the right-upstream (2/1) sensor, install plastic inner fender liner, and right-front tire/wheel. 4. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3923 Transmission Position Switch/Sensor: Diagrams Connector (HEV) - (TRANSMISSION SIDE) 12 WAY SENSOR-TRANSMISSION RANGE (HEV) - (TRANSMISSION SIDE) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Description DESCRIPTION The transmission range sensor (2) is located inside the transmission and connects to the mainshaft (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description > Page 3926 Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Disconnect the transmission range sensor electrical connector (1). 3. Remove the bolt (1) securing the transmission range sensor (2) to the mainshaft (3). 4. Remove the mainshaft roll pin (1) from the transmission case (2) and remove the mainshaft. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3929 5. Lower the transmission range sensor (2) and remove the park actuator rod (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3930 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install the park actuator rod (3) into the transmission range sensor (2). 2. Install the mainshaft roll pin (1) to the transmission case (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3931 3. Position the transmission range sensor (2) into place in the transmission case. 4. Install the mainshaft (3) into the transmission case. 5. Install the transmission range sensor mounting bolt. Tighten the bolt to 8 Nm (71 NOTE: Before install the TEHCM / valve body assembly to the transmission case, be certain the existing gasket is in place. 6. Install the valve body. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 3935 Transmission Position Switch/Sensor: Diagrams Connector (HEV) - (TRANSMISSION SIDE) 12 WAY SENSOR-TRANSMISSION RANGE (HEV) - (TRANSMISSION SIDE) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Description DESCRIPTION The transmission range sensor (2) is located inside the transmission and connects to the mainshaft (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description > Page 3938 Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Disconnect the transmission range sensor electrical connector (1). 3. Remove the bolt (1) securing the transmission range sensor (2) to the mainshaft (3). 4. Remove the mainshaft roll pin (1) from the transmission case (2) and remove the mainshaft. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3941 5. Lower the transmission range sensor (2) and remove the park actuator rod (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3942 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install the park actuator rod (3) into the transmission range sensor (2). 2. Install the mainshaft roll pin (1) to the transmission case (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 3943 3. Position the transmission range sensor (2) into place in the transmission case. 4. Install the mainshaft (3) into the transmission case. 5. Install the transmission range sensor mounting bolt. Tighten the bolt to 8 Nm (71 NOTE: Before install the TEHCM / valve body assembly to the transmission case, be certain the existing gasket is in place. 6. Install the valve body. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Diagrams > Multi Displacement System Solenoid CYL 1 (5.7L MDS) (Multi Displacement Solenoid) 2 Way Valve Deactivation Solenoid: Diagrams Multi Displacement System Solenoid CYL 1 (5.7L MDS) (Multi Displacement Solenoid) 2 Way Connector (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY SOLENOID-MULTI DISPLACEMENT SYSTEM CYL 1 (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Diagrams > Multi Displacement System Solenoid CYL 1 (5.7L MDS) (Multi Displacement Solenoid) 2 Way > Page 3948 Valve Deactivation Solenoid: Diagrams Multi Displacement System Solenoid CYL 4 (5.7L MDS) (Multi Displacement Solenoid) 2 Way Connector (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY SOLENOID-MULTI DISPLACEMENT SYSTEM CYL 4 (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Diagrams > Multi Displacement System Solenoid CYL 1 (5.7L MDS) (Multi Displacement Solenoid) 2 Way > Page 3949 Valve Deactivation Solenoid: Diagrams Multi Displacement System Solenoid CYL 6 (5.7L MDS) (Multi Displacement Solenoid) 2 Way Connector (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY SOLENOID-MULTI DISPLACEMENT SYSTEM CYL 6 (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Diagrams > Multi Displacement System Solenoid CYL 1 (5.7L MDS) (Multi Displacement Solenoid) 2 Way > Page 3950 Valve Deactivation Solenoid: Diagrams Multi Displacement System Solenoid CYL 7 (5.7L MDS) (Multi Displacement Solenoid) 2 Way Connector (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY SOLENOID-MULTI DISPLACEMENT SYSTEM CYL 7 (5.7L MDS) - (MULTI DISPLACEMENT SOLENOID) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Description and Operation > MDS System - Description Valve Deactivation Solenoid: Description and Operation MDS System - Description DESCRIPTION The Multiple Displacement System (MDS) provides cylinder deactivation during steady-speed, low-acceleration and shallow grade climbing conditions to increase fuel economy. MDS can provide a 5-20 percent fuel economy benefit when operating in four-cylinder mode, depending on driving habits and vehicle usage. For EPA rating purposes, fuel economy is 8-15 percent higher than if the engine was operating on eight cylinders at all times. MDS is integrated into the basic engine architecture, requiring a minimum of additional parts - four additional solenoids, an oil temperature sensor and a wire harness. Eight unique valve lifters and a modified camshaft are also required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Description and Operation > MDS System - Description > Page 3953 Valve Deactivation Solenoid: Description and Operation MDS System - Operation OPERATION The Multiple Displacement System (MDS) provides cylinder deactivation during steady speed, low acceleration and shallow grade climbing conditions to increase fuel economy. Both four and eight cylinder configurations have even firing intervals provide smooth operation. Two cylinders on each bank are active when the engine is in four-cylinder mode - every other cylinder in the firing order. All of the cylinders that are deactivated have unique hydraulic valve lifters that collapse when deactivated to prevent the valves from opening. Engine oil pressure is used to activate and deactivate the valves. It is delivered through special oil passages drilled into the cylinder block. Solenoid valves control the flow. When activated, pressurized oil pushes a latching pin on each valve lifter, which then becomes a "lost motion" link. Its base follows the camshaft, but its top remains stationary, held in place against the pushrod by light spring pressure but unable to move because of the much higher force of the valve spring. NOTE: It is critical to use the recommended oil viscosity in 5.7L engines that use MDS. Deactivation occurs during the compression stroke of each cylinder, after air and fuel enter the cylinder. Ignition then occurs, but the combustion products remain trapped in the cylinder under high pressure, because the valves no longer open. No air enters or leaves. During subsequent piston strokes, this high-pressure gas is repeatedly compressed and expanded like an air spring, but fuel is not injected. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Description and Operation > MDS System - Description > Page 3954 Valve Deactivation Solenoid: Description and Operation Multiple Displacement Solenoid Description DESCRIPTION The Multi Displacement System selectively deactivates cylinders 1,4,6, and 7, to improve fuel economy. It has two modes of operation: - 8 cylinders for acceleration and heavy loads. - 4 cylinders for cruising and city traffic. The main components of the Multi Displacement System are: - Unique MDS camshaft. - Deactivating roller tappets. - 4 control valves/solenoids. - control valve/solenoid wiring harness. - oil temp sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Description and Operation > MDS System - Description > Page 3955 Valve Deactivation Solenoid: Description and Operation Multiple Displacement Solenoid Operation OPERATION Cylinder Deactivation - Trap an exhaust charge from a normal combustion event - Normal combustion event - Don't open the exhaust valve - Don't open the intake valve - Piston is an air spring - Cylinders deactivated in firing sequence Cylinder Reactivation - Open the exhaust valve - Empty the cylinder - Open the intake valve - Normal combustion event - Cylinders reactivated in firing sequence Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Description and Operation > Page 3956 Valve Deactivation Solenoid: Testing and Inspection MDS SOLENOID The Multi-Displacement System (MDS) has the following detectable issues: - solenoid circuit - fail to deactivate a cylinder(s) - fail to reactivate a cylinder(s) - low oil pressure Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Service and Repair > Multiple Displacement Solenoid - Removal Valve Deactivation Solenoid: Service and Repair Multiple Displacement Solenoid - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Removal and Replacement/Intake Manifold - Removal 3. Remove the intake manifold foam insulator pad (1). 4. Remove the electrical connector (1) from the Multi Displacement System (MDS) solenoid(s) (2). 5. Remove the MDS solenoid(s) retaining bolt (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Service and Repair > Multiple Displacement Solenoid - Removal > Page 3959 CAUTION: Do not try to pry the solenoid out. This could lead to breakage and contamination of the lubrication system. 6. While pulling up, rotate the MDS solenoid from side-to-side and remove the MDS solenoid(s) from the cylinder block. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Valve Deactivation Solenoid > Component Information > Service and Repair > Multiple Displacement Solenoid - Removal > Page 3960 Valve Deactivation Solenoid: Service and Repair Multiple Displacement Solenoid - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Verify that the Multi Displacement System (MDS) bores are free of debris before installing the MDS solenoid(s). 2. Install the MDS solenoid(s) (3) making sure the solenoid is completely seated into the cylinder block. 3. Install the MDS solenoid retaining bolt(s) (2) and tighten to 11 Nm (8 ft. lbs.). 4. Connect the MDS electrical connector to the solenoid(s) (3). 5. Install the foam insulator pad (1). 6. Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Removal and Replacement/Intake Manifold - Installation 7. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Valve Timing Assembly - Description Variable Valve Timing Actuator: Description and Operation Variable Valve Timing Assembly Description DESCRIPTION The 5.7L Eagle engine is equipped with Variable Cam Timing (VCT). This system advances and/or retards the camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The VCT assembly is sometimes referred to as a camshaft phaser. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. The VCT assembly consists of the camshaft sprocket and a timing phaser. The VCT phaser assembly bolts to the camshaft and is serviced as an assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Valve Timing Assembly - Description > Page 3965 Variable Valve Timing Actuator: Description and Operation Variable Valve Timing Assembly Operation OPERATION The Variable Cam Timing (VCT) assembly is actuated with engine oil pressure. The oil flow to the VCT assemblies are controlled by an Oil Control Valve (OCV). The OCV consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VCT assemblies. The VCT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VCT assembly rotates the rotor with respect to the stator, thus rotating the exhaust camshaft with respect to the timing chain and intake camshaft. An infinitely variable cam timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Service and Repair > Variable Valve Timing Assembly - Removal Variable Valve Timing Actuator: Service and Repair Variable Valve Timing Assembly - Removal REMOVAL CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. 1. Remove the timing chain and sprockets See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Chain/Service and Repair/Timing Chain & Sprockets - Removal 2. Remove the camshaft phaser bolt (1). 3. Remove camshaft phaser (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator > Component Information > Service and Repair > Variable Valve Timing Assembly - Removal > Page 3968 Variable Valve Timing Actuator: Service and Repair Variable Valve Timing Assembly - Installation INSTALLATION 1. Align the slot (2) in the phaser (1) with the dowel on the camshaft. CAUTION: Never attempt to disassemble the camshaft phaser, severe engine damage could result. 2. Position the phaser (2) in place and install phaser retaining bolt (1) and tighten to 122 Nm (90 ft. lbs.). 3. Install the timing chain and sprockets See: Engine, Cooling and Exhaust/Engine/Timing Components/Timing Chain/Service and Repair/Timing Chain & Sprockets - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Diagrams Variable Valve Timing Solenoid: Diagrams Connector (5.7L) - 2 WAY SOLENOID-VARIABLE CAMSHAFT TIMING (5.7L) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation > Oil Intake Control Valve - Operation Variable Valve Timing Solenoid: Description and Operation Oil Intake Control Valve - Operation OPERATION The Variable Valve Timing (VVT) assembly is actuated with engine oil pressure. The oil flow to the VVT assemblies are controlled by an Oil Control Valve (OCV). The OCV consist of a Pulse Width Modulated (PWM) solenoid and a spool valve. The PCM actuates the OCV to control oil flow through the spool valve into the VVT assemblies. The VVT assembly consists of a rotor, stator, and sprocket. The stator is connected to the timing chain through the sprocket. The rotor is connected to the camshaft. Oil flow in to the VVT assembly rotates the rotor with respect to the stator, thus rotating the exhaust camshaft with respect to the timing chain and intake camshaft. An infinitely variable valve timing position can be achieved within the limits of the hardware. The CMP monitors the position of the camshaft with respect to the crankshaft and provides feedback to the PCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Description and Operation > Oil Intake Control Valve - Operation > Page 3974 Variable Valve Timing Solenoid: Description and Operation Oil Intake Control Valve - Description DESCRIPTION The 5.7L engine is equipped with Variable Valve Timing (VVT). This system uses an oil control valve to direct oil pressure into the camshaft phaser assembly. The camshaft phaser assembly advances and/or retards camshaft timing to improve engine performance, mid-range torque, idle quality, fuel economy, and reduce emissions. The oil control valve is located under the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Oil Intake Control Valve - Installation Variable Valve Timing Solenoid: Service and Repair Oil Intake Control Valve - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Install the oil control valve (OCV) (1). 2. Securely tighten the OCV fastener. 3. Connect the OCV electrical connector (2). 4. Install the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Removal and Replacement/Intake Manifold - Installation 5. Connect the 12 volt battery system ground isolation connector (1) located next to the electric vacuum pump (2). 6. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Oil Intake Control Valve - Installation > Page 3977 Variable Valve Timing Solenoid: Service and Repair Oil Intake Control Valve - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the fuel system pressure release procedure See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect the 12 volt battery system ground isolation connector (1) located next to the electric vacuum pump (2). 3. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 4. Remove the intake manifold See: Engine, Cooling and Exhaust/Engine/Intake Manifold/Service and Repair/Removal and Replacement/Intake Manifold - Removal 5. Disconnect the oil control valve (OCV) electrical connector (2). 6. Remove the OCV fastener (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid > Component Information > Service and Repair > Oil Intake Control Valve - Installation > Page 3978 NOTE: To remove the oil control valve, the engine must be at room temperature. 7. Rotate the OCV to break the seal and pull the OCV out of the cylinder block. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Description Catalytic Converter: Description and Operation Description DESCRIPTION All vehicles incorporate toeboard catalytic converters into the exhaust system. These catalytic converters are made of stainless steel designed to operate at extremely high temperatures. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Description > Page 3984 Catalytic Converter: Description and Operation Operation OPERATION The catalytic converter captures and burns any unburned fuel mixture exiting the combustion chambers during the exhaust stroke of the engine. This process aids in reducing emissions output. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 3985 Catalytic Converter: Testing and Inspection INSPECTION Look at the stainless steel body of the converter, inspect for bulging or other distortion that could be a result of overheating. If the converter has a heat shield attached make sure it is not bent or loose. If you suspect internal damage to the catalyst, tapping the bottom of the catalyst with a rubber mallet may indicate a damaged core. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter - Removal Catalytic Converter: Service and Repair Catalytic Converter - Removal 5.7L HEV To remove the RH catalytic converter it is necessary to remove the transmission. 1. Disconnect negative batter cable. 2. Raise and support the vehicle. 3. Saturate all exhaust bolts and nuts with Mopar(R) Rust Penetrant. Allow 5 minutes for penetration. 4. Disconnect the oxygen sensor electrical connectors. 5. Remove the clamp (3) holding the LH catalytic converter (4) to the RH catalytic converter (2). 6. Remove the catalytic converter-to-manifold bolts (1). 7. Remove the LH catalytic converter (4) from the RH catalytic converter (2). 8. Remove the transmission See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement/Removal. 9. Remove the clamp holding the RH catalytic converter (2) to the exhaust pipe(s). 10. Remove the RH catalytic converter (2) from the extension pipe. 11. Remove the RH catalytic converter from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Service and Repair > Catalytic Converter - Removal > Page 3988 Catalytic Converter: Service and Repair Catalytic Converter - Installation 5.7L HEV The band clamps are not reusable. After removal, the must be replaced. 1. Remove any burrs from the RH (2) and LH (4) catalytic converter. 2. Position RH catalytic converter to exhaust manifold. 3. Install catalytic converter to manifold bolts and nuts. Hand tighten at this time. 4. Install transmission See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement/Installation. 5. Position new RH catalytic converter-to-exhaust pipe clamp on exhaust pipe. Insert the RH (2) catalytic converter into the exhaust pipe. Do not tighten clamp at this time. 6. Make sure the alignment tang is seated in the alignment slot. 7. Position new RH catalytic converter-to-LH catalytic converter clamp on RH catalytic converter. Insert the LH catalytic converter (4) into the RH catalytic converter (2). Do not tighten clamp at this time. 8. Make sure the alignment tang is seated in the alignment slot. 9. Install the LH and RH catalytic converters (2 and 4) to the exhaust manifold. Install bolts. Do not tighten at this time. 10. Connect the oxygen sensor electrical connectors. 11. Make sure the catalytic converter assembly (2 and 4) are correctly positioned and the properly aligned. The minimum clearance between components is 25mm (1 inch). Ensure that the exhaust crossover has at least 15mm (.59 in.) clearance at transmission crossmember. Ensure that muffler isolators are not stretched. Measurement between insulator rods is approximately 42mm (1.65 in.). Make the necessary adjustments, if necessary. 12. 10. Tighten manifold flange bolts to 34 Nm (24 lbs. ft.). Tighten the new exhaust clamps to 61 Nm (45 lbs. ft). 13. Start the engine, inspect for exhaust leaks. Repair exhaust leaks as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > EVAP Purge Solenoid (Headlamp And Dash) 2 Way Canister Purge Solenoid: Diagrams EVAP Purge Solenoid (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SOLENOID-EVAP/PURGE - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > EVAP Purge Solenoid (Headlamp And Dash) 2 Way > Page 3995 Canister Purge Solenoid: Diagrams Fuel Tank Isolation Solenoid (HEV) (Chassis) 2 Way Connector (HEV) - (CHASSIS) 2 WAY SOLENOID-FUEL TANK ISOLATION (HEV) - (CHASSIS) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Diagrams > Page 3996 Canister Purge Solenoid: Description and Operation DESCRIPTION - HEV The fuel tank isolation valve is used to isolate the fuel tank from the rest of the evaporative emissions system and can be commanded to close or remain open under a variety of circumstances or driving conditions. The fuel tank isolation valve has an Automatic Shutdown (ASD) relay power feed and is controlled by a PWM ground signal from the PCM. During periods of operation when the engine is not running (electric-only mode), there is potential for large quantities of fuel vapor to be generated in the fuel tank that may exceed the capacity of the charcoal canister. The isolation valve is used to prevent fuel vapors from escaping the system. The isolation valve blocks the vapor path from the tank to the charcoal canister, thereby keeping the vapors in the tank. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Evap Purge Solenoid - Removal Canister Purge Solenoid: Service and Repair Evap Purge Solenoid - Removal REMOVAL The duty cycle EVAP canister purge solenoid (1) is located in the engine compartment. It is attached to a tongue-type bracket near the brake power booster (3). 1. Carefully pull the solenoid assembly straight forward from the tongue-type bracket without bending the two vapor lines. 2. Disconnect electrical wiring connector (2) at solenoid. 3. Disconnect vapor line quick-connect fitting (4) at solenoid. 4. Disconnect vapor line quick-connect fitting (5) at solenoid. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Evap Purge Solenoid - Removal > Page 3999 Canister Purge Solenoid: Service and Repair Evap Purge Solenoid - Installation INSTALLATION The duty cycle EVAP canister purge solenoid (1) is located in the engine compartment. It is attached to a tongue-type bracket near the brake power booster (3). 1. Connect vapor line quick-connect fitting (5) to solenoid. 2. Connect vapor line quick-connect fitting (4) to solenoid. 3. Connect electrical wiring connector (2) to solenoid. 4. Carefully push the solenoid assembly straight rearward onto the tongue-type bracket without bending the two vapor lines. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Evap Purge Solenoid - Removal > Page 4000 Canister Purge Solenoid: Service and Repair Fuel Tank Isolation Valve - Removal REMOVAL - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the fuel system pressure release procedure See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 3. Raise and support vehicle. The EVAP canister is located at the front of the fuel tank. The Evaporative System Integrity Monitor (ESIM) switch is attached to the EVAP canister. 4. Disconnect the rubber hose (1) at the ESIM switch. 5. Disconnect the electrical connector (2) at the ESIM switch. 6. Disconnect the fuel tank isolation valve quick-connect fitting (3) at the EVAP canister. 7. Disconnect the fuel tank isolation valve vapor line quick-connect fitting (1) to the purge solenoid tubing connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Evap Purge Solenoid - Removal > Page 4001 8. Disconnect the fuel tank isolation valve quick-connect fitting (1) at the fuel tank. 9. Disconnect the fuel tank isolation valve electrical connector (2) at the EVAP canister mounting bracket. 10. Remove the EVAP canister mounting bracket retaining nuts/bolts (1). 11. Remove the EVAP canister (1), fuel tank isolation valve (2) and ESIM (3) as an assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Evap Purge Solenoid - Removal > Page 4002 12. Remove the fuel tank isolation valve from the EVAP canister mounting bracket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Evap Purge Solenoid - Removal > Page 4003 Canister Purge Solenoid: Service and Repair Fuel Tank Isolation Valve - Installation INSTALLATION - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Slide the fuel tank isolation valve onto the EVAP canister mounting bracket. 2. If removed, connect the pig tail electrical connector (2) to the fuel tank isolation valve. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Evap Purge Solenoid - Removal > Page 4004 3. Install the EVAP canister (1), fuel tank isolation valve (2) and the Evaporative System Integrity Monitor (ESIM) switch (3) as an assembly. 4. Position the EVAP canister to the fuel tank and securely tighten the two retaining bolts/nuts (1). 5. Connect the fuel tank isolation valve quick-connect fitting (1) at the fuel tank. 6. Connect the fuel tank isolation valve electrical connector (2) at the EVAP canister mounting bracket. 7. Connect the fuel tank isolation valve vapor line quick-connect fitting (1) to the purge solenoid tubing connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Evap Purge Solenoid - Removal > Page 4005 8. Connect the fuel tank isolation valve quick-connect fitting (3) at the EVAP canister. 9. Connect the electrical connector (2) at the ESIM switch. 10. Connect the rubber hose (1) at the ESIM switch. 11. Lower the vehicle. 12. Install the fuel fill cap. 13. Connect the fuel line quick connect fitting to the fuel rail (1). 14. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 15. Start the engine and check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Check Valve: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4014 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4015 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Check Valve: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4021 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Check Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Check Valve: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4022 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations Evaporative Emission Control Canister: Locations The EVAP canister (1) is located at the front of the fuel tank. The fuel tank isolation valve (2) and the Evaporative System Integrity Monitor (ESIM) switch (3) are attached to the EVAP canister. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Locations > Page 4026 Evaporative Emission Control Canister: Description and Operation OPERATION The EVAP canister is filled with granules of an activated carbon mixture. Fuel vapors entering the EVAP canister is absorbed by the charcoal granules. Fuel tank pressure vents into the EVAP canister. Fuel vapors are temporarily held in the canister until they can be drawn into the intake manifold. The duty cycle EVAP canister purge solenoid allows the EVAP canister to be purged at predetermined times and at certain engine operating conditions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal Evaporative Emission Control Canister: Service and Repair Removal REMOVAL - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions The EVAP canister (1) is located at the front of the fuel tank. The fuel tank isolation valve (2) and the Evaporative System Integrity Monitor (ESIM) switch (3) are attached to the EVAP canister. 1. Perform the fuel system pressure release procedure See: Fuel Delivery and Air Induction/Fuel Filter/Fuel Pressure Release/Service and Repair 2. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 3. Raise and support the vehicle. 4. Disconnect the rubber hose (1) at the ESIM switch. 5. Disconnect the electrical connector (2) at the ESIM switch. 6. Disconnect the fuel tank isolation valve quick-connect fitting (3) at the EVAP canister. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 4029 7. Disconnect the fuel tank isolation valve vapor line quick-connect fitting (1) to the purge solenoid tubing connector. 8. Disconnect the fuel tank isolation valve quick-connect fitting (1) at the fuel tank. 9. Disconnect the fuel tank isolation valve electrical connector (2) at the EVAP canister mounting bracket. 10. Remove the EVAP canister bracket retaining nuts/bolts (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 4030 11. Remove the EVAP canister (1), fuel tank isolation valve (2) and ESIM (3) as an assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 4031 Evaporative Emission Control Canister: Service and Repair Installation INSTALLATION - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions NOTE: Install the EVAP canister (1), fuel tank isolation valve (2) and the Evaporative System Integrity Monitor (ESIM) switch (3) as an assembly. 1. Position the EVAP canister (1), fuel tank isolation valve (2) and the ESIM switch (3) as an assembly onto the fuel tank, install the canister mounting bracket retaining nuts/bolts (1) and securely tighten. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 4032 2. Connect the fuel tank isolation valve quick-connect fitting (1) at the fuel tank. 3. Connect the fuel tank isolation valve electrical connector (2) at the EVAP canister mounting bracket. 4. Connect the fuel tank isolation valve vapor line quick-connect fitting (1) to the purge solenoid tubing connector. NOTE: All vapor/vacuum lines and hoses must be firmly connected. Also check the vapor/vacuum lines at the EVAP canister purge solenoid for damage or leaks. If a leak is present, a Diagnostic Trouble Code (DTC) may be set. 5. Connect the rubber hose (1) at the ESIM switch. 6. Connect the electrical connector (2) at the ESIM switch. 7. Connect the fuel tank isolation valve quick-connect fitting (3) at the EVAP canister. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Service and Repair > Removal > Page 4033 8. Lower the vehicle. 9. Install the fuel fill cap. 10. Connect the fuel line quick connect fitting to the fuel rail (1). 11. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 12. Start the engine and check for leaks at all vapor, vacuum and fuel line connections. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Emissions Hose: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4042 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4043 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Evaporative Emissions Hose: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4049 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4050 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 4054 Leak Detector: Diagrams Connector - (ENGINE) 2 WAY SWITCH-EVAP SYSTEM MONITOR - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 4055 Leak Detector: Description and Operation OPERATION SYSTEM The ESIM (Evaporative System Integrity Monitor) is very similar to the NVLD. However, the design of the ESIM has been simplified and unlike the NVLD the ESIM does not require a solenoid. The ESIM mounts directly to the canister, eliminating the need for a mounting bracket. It is critical that the ESIM is mounted vertically. On vehicles where the canister is mounted on an angle, the ESIM requires an adaptor to maintain a vertical position. When the ESIM is installed vertically, the electrical connector is in the 3 o'clock position. EXPLODED VIEW Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 4056 The ESIM assembly consists of a housing, a small weight and a large weight that serve as check valves, a diaphragm, a switch and a cover. There is one large weight and one small weight check valve in the ESIM assembly. A seal is attached at the end of each weighted check valve. The large weight check valve seals for pressure. The small weight check valve seals for vacuum. The weighted check valves are contained within the ESIM housing. CUT AWAY OF MODULE The ESIM (Evaporative System Integrity Monitor), while physically different than the NVLD system, performs the same basic function as the NVLD does - controlling evaporative emissions. The ESIM has been simplified because the solenoid used on the NVLD is not used on the ESIM. The ESIM consists of housing, two check valves (sometimes referred to as weights), a diaphragm, a switch and a cover. The larger check valve seals for pressure and the smaller one seals for vacuum. During refueling, pressure is built up in the evaporative system. When pressure reaches approximately.5 inches of water, the large check valve unseats and pressure vents to the fresh air filter. Conversely, when the system cools, and the resulting vacuum lifts the small check valve from its seat and allows fresh air to enter the system and relieves the vacuum condition. When a calibrated amount of vacuum is achieved in the evaporative system, the diaphragm is pulled inward, pushing on the spring and closing the contacts. The ESIM conducts test on the evaporative system as follows: An engine off, non-intrusive test for small leaks and an engine running, intrusive test for medium/large leaks. The ESIM weights seal the evap. system during engine off conditions. If the evap. system is sealed, it will be pulled into a vacuum, either due to the cool down from operating temperature or diurnal ambient temperature cycling. When the vacuum in the system exceeds about 1" H20, the vacuum switch closes. The switch closure sends a signal to the PCM. In order to pass the non-intrusive small leak test, the ESIM switch must close within a calculated amount of time and within a specified amount of key-off events. If the ESIM switch does not close as specified, the test is considered inconclusive and the intrusive engine running test will be run during the next key-on cycle. This intrusive test will run on the next cold engine running condition. Conditions for running the intrusive test are: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Locations > Page 4057 - After the vehicle is started, the engine coolant temperature must be within 50°F (10°C) of ambient to indicate a cold start. - The fuel level must be between 12% and 88%. - The engine must be in closed loop. - Manifold vacuum must be greater than a minimum specified value. - Ambient temperature must be between 39°F and 98°F (4°C and 37°C) and the elevation level must be below 8500 feet (2591 meters). The test is accomplished by the PCM activating the purge solenoid to create a vacuum in the evaporative system. The PCM then measures the amount of time it takes for the vacuum to dissipate. This is known as the vacuum decay method. If the switch opens quickly a large leak is recorded. If the switch opens after a predetermined amount of time, then the small leak matures. If the switch does not close, then a general evaporative failure is recorded. The purge monitor tests the integrity of the hose attached between the purge valve and throttle body/intake. The purge monitor is a two stage test and it runs only after the evaporative system passes the small leak test. Even when all of the thresholds are met, a small leak won't be recorded until after the medium/large leak monitor has been run. This is accomplished by the PCM activating the purge solenoid to create a vacuum in the evaporative system. The PCM then measures the amount of time it takes for the vacuum to dissipate. This is known as the vacuum decay method. If the switch opens quickly a large leak is recorded. If the switch opens after a predetermined amount of time, then the small leak matures. If the medium/large leak test runs and the ESIM switch doesn't close, a general evaporative test is run. The purge solenoid is activated for approximately 10 seconds, increasing the amount of vacuum in the system. If the ESIM switch closes after the extended purge activation, a large leak fault is generated. If the switch doesn't close, a general evaporative system fault is generated. The purge monitor tests the integrity of the hose attached between the purge valve and throttle body/intake. The purge monitor is a two stage test and it runs only after the evaporative system passes the small leak test. Stage one of the purge monitor is non-intrusive. The PCM monitors the purge vapor ratio. If the ratio is above a calibrated specification, the monitor passes. Stage two is an intrusive test and it runs only if stage one fails. During the stage two test, the PCM commands the purge solenoid to flow at a specified rate to force the purge vapor ratio to update. The vapor ratio is compared to a calibrated specification and if it is less than specified, a one-trip failure is recorded. The ESIM switch stuck closed monitor checks to see if the switch is stuck closed. This is a power down test that runs at key-off; when the PCM sees 0 rpm's, the purge solenoid is energized for a maximum of 30 seconds, venting any vacuum trapped in the evaporative system. If the switch opens or was open before the test began, the monitor passes. If the switch doesn't open, the monitor fails. This is a two-trip MIL. The star scan tool can be used to force the ESIM switch stick closed monitor to run. The PCM also uses the ESIM to detect a loose or missing gas cap. The PCM controller looks for a change in the fuel level (25% minimum) and then gas cap is loose or missing. If a medium/large leak is detected, a loose gas cap light illuminates and a pending one-trip fault code is set. On the PCM, this is a three-trip fault before the code matures Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Service and Repair > Removal Leak Detector: Service and Repair Removal REMOVAL The ESIM (EVAP System Integrity Monitor) switch is attached to the Evap canister and is usually not serviceable. Replace the switch by replacing the Evap canister. See Evap canister removal/installation. If servicing separately, refer to the following: The ESIM switch (2) is located on the Evap canister (1) The picture displays a typical Evap Canister and a typical ESIM switch. 1. Remove both plastic lines from switch by folding line tabs (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Service and Repair > Removal > Page 4060 2. Disconnect electrical connector at switch. 3. Clean any dirt from ESIM switch and its lines. 4. A lock tab (see arrow) is used on the back of the switch. Push lock tab towards switch while rotating switch counterclockwise 1/4 turn for removal. 5. The fresh air lines and hoses from the ESIM must have a clear opening to the atmosphere. Check the fresh air lines, including the fresh air filter, for obstructions or restrictions at the ESIM. Also check the routing to the exit to atmosphere. If a restriction is present, the system will not allow free flow passage of clean air, and an early shut off of the fuel fill nozzle may occur during fuel fill. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak Detector, Evaporative System > Component Information > Service and Repair > Removal > Page 4061 Leak Detector: Service and Repair Installation INSTALLATION The following pictures display a TYPICAL EVAP Canister and a typical ESIM switch. After installing any ESIM switch, the electrical connector on the switch must be in the 3 O'clock position. This step must be done for proper ESIM switch operation. 1. The fresh air lines and hoses from the ESIM must have a clear opening to the atmosphere. Check the fresh air lines, including the fresh air filter, for obstructions or restrictions at the ESIM. Also check the routing to the exit to atmosphere. If a restriction is present, the system will not allow free flow passage of clean air, and an early shut off of the fuel fill nozzle may occur during fuel fill. 2. Be sure O-ring (2) and EVAP canister opening are clean. CAUTION: The electrical connector (3) on the ESIM switch must be in 3 O'clock position after installation. This step must be done for proper switch operation. 3. Position ESIM switch (2) into EVAP canister (1) and rotate until electrical connector is in 3 O'clock position (3). 4. Connect electrical connector. 5. Connect plastic lines to ESIM switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation > Description Refueling Vapor Recovery System: Description and Operation Description DESCRIPTION The ORVR (On-Board Refueling Vapor Recovery) system consists of a unique fuel tank, flow management valve, fluid control valve, one-way check valve and vapor canister. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Refueling Vapor Recovery System > System Information > Description and Operation > Description > Page 4066 Refueling Vapor Recovery System: Description and Operation Operation OPERATION The ORVR (On-Board Refueling Vapor Recovery) system is used to remove excess fuel tank vapors. This is done while the vehicle is being refueled. Fuel flowing into the fuel filler tube (approx. 1" I.D.) creates an aspiration effect drawing air into the fuel fill tube. During refueling, the fuel tank is vented to the EVAP canister to capture escaping vapors. With air flowing into the filler tube, there are no fuel vapors escaping to the atmosphere. Once the refueling vapors are captured by the EVAP canister, the vehicle's computer controlled purge system draws vapor out of the canister for the engine to burn. The vapor flow is metered by the purge solenoid so that there is no, or minimal impact on driveability or tailpipe emissions. As fuel starts to flow through the fuel fill tube, it opens the normally closed check valve and enters the fuel tank. Vapor or air is expelled from the tank through the control valve and on to the vapor canister. Vapor is absorbed in the EVAP canister until vapor flow in the lines stops. This stoppage occurs following fuel shut-off, or by having the fuel level in the tank rise high enough to close the control valve. This control valve contains a float that rises to seal the large diameter vent path to the EVAP canister. At this point in the refueling process, fuel tank pressure increases, the check valve closes (preventing liquid fuel from spitting back at the operator), and fuel then rises up the fuel filler tube to shut off the dispensing nozzle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Description and Operation > Exhaust Gas Recirculation (EGR) Valve Description EGR Control Solenoid: Description and Operation Exhaust Gas Recirculation (EGR) Valve Description DESCRIPTION The Hybrid Electric Vehicle (HEV) uses a High Flow EGR valve. The High Flow EGR valve can only be used on the HEV engine and is not compatible with any other engine applications. The High Flow EGR valve consists of three components. First, there is the pintle, valve seat, and housing which contains and regulates the gas flow. Second, there is the armature, return spring, and solenoid coil to provide the operating force to regulate the flow by changing the pintle position. The solenoid coil assembly is in parallel with a diode and connects the two connectors in the connector assembly. Third, there is the pintle position sensor which senses pintle position and is connected to the three connectors in the electrical connector assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Description and Operation > Exhaust Gas Recirculation (EGR) Valve Description > Page 4072 EGR Control Solenoid: Description and Operation Exhaust Gas Recirculation (EGR) Valve Operation OPERATION - HEV NOTE: The Hybrid Electric Vehicle (HEV) uses a High Flow EGR valve. The High Flow EGR valve can only be used on the HEV engine and is not compatible with any other engine applications. The exhaust gas recirculation flow is determined by the engine controller. For a given set of conditions, the engine controller knows the ideal exhaust gas recirculation flow to optimize NOx and fuel economy as a function of the pintle position. Pintle position is obtained from the position sensor. The engine controller adjusts the duty cycle of 128 Hz power supplied to the solenoid coil to obtain the correct pintle position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Valve - Removal EGR Control Solenoid: Service and Repair Exhaust Gas Recirculation (EGR) Valve - Removal REMOVAL - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the HEV High Voltage Power Down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the 12 volt battery system ground isolation connector (1) located next to the electric vacuum pump (2). NOTE: The Hybrid Electric Vehicle (HEV) uses a High Flow EGR valve. The High Flow EGR valve can only be used on the HEV engine and is not compatible with any other engine applications. 3. Disconnect the EGR valve electrical connector (1). 4. Remove the EGR routing tube (2) retainers. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Valve - Removal > Page 4075 5. Remove the EGR valve retainers (2) and remove EGR valve (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Valve - Removal > Page 4076 EGR Control Solenoid: Service and Repair Exhaust Gas Recirculation (EGR) Valve - Installation INSTALLATION - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions NOTE: The Hybrid Electric Vehicle (HEV) uses a High Flow EGR valve. The High Flow EGR valve can only be used on the HEV engine and is not compatible with any other engine applications. 1. Position the EGR valve (1) in place and securely tighten retainers (2). 2. Position the EGR routing tube (2) and securely tighten retainers. 3. Connect the EGR valve electrical connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Valve - Removal > Page 4077 4. Connect the 12 volt battery system ground isolation connector (1) located next to the electric vacuum pump (2). 5. Perform the HEV High Voltage Power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Locations > Page 4081 EGR Valve: Diagrams Connector - (ENGINE) 6 WAY ASSEMBLY-EGR VALVE - (ENGINE) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Exhaust Gas Recirculation (EGR) Valve - Description EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) Valve - Description DESCRIPTION The Hybrid Electric Vehicle (HEV) uses a High Flow EGR valve. The High Flow EGR valve can only be used on the HEV engine and is not compatible with any other engine applications. The High Flow EGR valve consists of three components. First, there is the pintle, valve seat, and housing which contains and regulates the gas flow. Second, there is the armature, return spring, and solenoid coil to provide the operating force to regulate the flow by changing the pintle position. The solenoid coil assembly is in parallel with a diode and connects the two connectors in the connector assembly. Third, there is the pintle position sensor which senses pintle position and is connected to the three connectors in the electrical connector assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Exhaust Gas Recirculation (EGR) Valve - Description > Page 4084 EGR Valve: Description and Operation Exhaust Gas Recirculation (EGR) Valve - Operation OPERATION - HEV NOTE: The Hybrid Electric Vehicle (HEV) uses a High Flow EGR valve. The High Flow EGR valve can only be used on the HEV engine and is not compatible with any other engine applications. The exhaust gas recirculation flow is determined by the engine controller. For a given set of conditions, the engine controller knows the ideal exhaust gas recirculation flow to optimize NOx and fuel economy as a function of the pintle position. Pintle position is obtained from the position sensor. The engine controller adjusts the duty cycle of 128 Hz power supplied to the solenoid coil to obtain the correct pintle position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Valve - Removal EGR Valve: Service and Repair Exhaust Gas Recirculation (EGR) Valve - Removal REMOVAL - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the HEV High Voltage Power Down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the 12 volt battery system ground isolation connector (1) located next to the electric vacuum pump (2). NOTE: The Hybrid Electric Vehicle (HEV) uses a High Flow EGR valve. The High Flow EGR valve can only be used on the HEV engine and is not compatible with any other engine applications. 3. Disconnect the EGR valve electrical connector (1). 4. Remove the EGR routing tube (2) retainers. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Valve - Removal > Page 4087 5. Remove the EGR valve retainers (2) and remove EGR valve (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Valve - Removal > Page 4088 EGR Valve: Service and Repair Exhaust Gas Recirculation (EGR) Valve - Installation INSTALLATION - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions NOTE: The Hybrid Electric Vehicle (HEV) uses a High Flow EGR valve. The High Flow EGR valve can only be used on the HEV engine and is not compatible with any other engine applications. 1. Position the EGR valve (1) in place and securely tighten retainers (2). 2. Position the EGR routing tube (2) and securely tighten retainers. 3. Connect the EGR valve electrical connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Valve - Removal > Page 4089 4. Connect the 12 volt battery system ground isolation connector (1) located next to the electric vacuum pump (2). 5. Perform the HEV High Voltage Power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Locations Positive Crankcase Ventilation Valve: Locations The PCV valve (4) is mounted into the top of the intake manifold (1). This is located to the right / rear of the throttle body (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Positive Crankcase Ventilation (PCV) Valve - Removal Positive Crankcase Ventilation Valve: Service and Repair Positive Crankcase Ventilation (PCV) Valve - Removal REMOVAL The PCV valve (4) is mounted into the top of the intake manifold (1). This is located to the right / rear of the throttle body (2). 1. The PCV valve is sealed to the intake manifold with 2 O-rings (2). 2. Remove PCV valve by rotating counter-clockwise 90 degrees until locating tabs (3) have been freed. After tabs have cleared, pull valve straight up from intake manifold. 3. After valve is removed, check condition of 2 valve O-rings (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Positive Crankcase Ventilation (PCV) Valve - Removal > Page 4096 Positive Crankcase Ventilation Valve: Service and Repair Positive Crankcase Ventilation (PCV) Valve - Installation INSTALLATION 1. Clean out intake manifold opening. 2. Check condition of two o-rings on PCV valve. 3. Apply engine oil to two o-rings. 4. Place PCV valve into intake manifold and rotate 90 degrees clockwise for installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE The correct fuel pressure for this vehicle is 58 psi +/- 2 psi Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 4101 Fuel Pressure: Testing and Inspection FUEL PRESSURE LEAK DOWN For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: Follow these safety precautions to reduce the risk of fire and serious possible serious or fatal injury when performing this test procedure. Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. Use extreme caution when connecting and disconnecting fuel lines. - Considerable fuel leakage may occur when servicing the fuel system. Wear protective eye wear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair / replace as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A 1. Turn the ignition off. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 4102 WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from Gas and Diesel Fuel Pressure/Decay Tester 8978A. Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978A-1 (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect the Reservoir Assembly 534960 (4) to the Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 4103 - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 2. Turn the ignition on, wait five seconds, turn the ignition off and then wait 1 minute before proceeding. 3. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 Kpa +/- 34 Kpa (59 psi +/- 5 psi). SRT-4 fuel pressure specification is 552 Kpa +/- 34 Kpa (80 psi +/- 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the Checking The Fuel Delivery System diagnostic procedure as directed. 5. CHECK FUEL DELIVERY SYSTEM FOR LEAK DOWN WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Close the Fuel System Isolation Valve (1) and then wait five minutes before proceeding. 2. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge (1) - Replace the fuel pump module. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Yes - On Fuel Outlet Gauge (2) - Replace the leaking fuel injector(s). - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. No - If directed here by another test, return to that test. Otherwise, test complete. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions Use the following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove the fuel fill cap. 2. Remove the fuel pump relay or the fuel pump speed relay from the Power Distribution Center (PDC) (1), refer to the label on the underside of the PDC cover for relay locations or See: Maintenance/Fuses and Circuit Breakers/Fuse/Locations/Fuse Panel 3. Start and run the engine until it stalls. 4. Attempt restarting the engine until it will no longer run. 5. Turn the ignition key to the OFF position. 6. Disconnect the 12 volt battery system ground isolation connector (1). 7. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down NOTE: Excessive fuel spillage onto the gaskets can cause gaskets to expand and dislodge from gasket groove. 8. Place a rag or towel around the fuel line quick-connect fitting at the fuel rail to prevent residual fuel spray or spillage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Page 4107 9. Disconnect the fuel supply line quick connect fitting at the fuel rail (1) and plug the fuel supply line with a shipping cap See: Fuel Line Coupler/Service and Repair 10. Return the fuel pump relay or the fuel pump speed relay to the PDC. NOTE: One or more Diagnostic Trouble Code(s) (DTC) may have been stored in the PCM memory due to the fuel pump relay removal. A diagnostic scan tool must be used to erase a DTC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Removal - Without Accelerator Pedal Position Sensor Accelerator Pedal: Service and Repair Removal - Without Accelerator Pedal Position Sensor WITHOUT ACCELERATOR PEDAL POSITION SENSOR (APPS) The accelerator pedal is serviced as a complete assembly including the bracket. The accelerator cable is connected to the upper part of the accelerator pedal arm by a plastic retainer (clip) (7). This plastic retainer snaps into the top of the accelerator pedal arm. 1. From inside the vehicle, hold up accelerator pedal. Remove plastic cable retainer (clip) (7) and throttle cable core wire from upper end of accelerator pedal arm (6). Plastic cable retainer (clip) snaps into pedal arm. 2. Remove two accelerator pedal mounting bracket nuts (5). Remove accelerator pedal assembly (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Removal - Without Accelerator Pedal Position Sensor > Page 4112 Accelerator Pedal: Service and Repair Installation - Without Accelerator Pedal Position Sensor WITHOUT ACCELERATOR PEDAL POSITION SENSOR (APPS) The accelerator cable is connected to the upper part of the accelerator pedal arm by a plastic retainer (clip) (7). This plastic retainer snaps into the top of the accelerator pedal arm. 1. Place accelerator pedal assembly (4) over two mounting studs (3). 2. Install and tighten two mounting nuts (5). Refer to Torque Specifications. 3. Slide throttle cable into opening slot (6) in top of pedal arm. 4. Push plastic cable retainer (clip) (7) into accelerator pedal arm opening until it snaps into place. 5. Before starting engine, operate accelerator pedal to check for any binding. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Removal - Without Accelerator Pedal Position Sensor > Page 4113 Accelerator Pedal: Service and Repair Removal - With Accelerator Pedal Position Sensor WITH ACCELERATOR PEDAL POSITION SENSOR (APPS) The accelerator pedal (4) is serviced as a complete assembly including the bracket and sensor. 1. Disconnect electrical connector (1) at APPS (6). 2. Remove two accelerator pedal mounting bracket nuts (5). Remove accelerator pedal assembly (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair > Removal - Without Accelerator Pedal Position Sensor > Page 4114 Accelerator Pedal: Service and Repair Installation - With Accelerator Pedal Position Sensor WITH ACCELERATOR PEDAL POSITION SENSOR (APPS) 1. Place accelerator pedal assembly (4) over two mounting studs (3). 2. Install and tighten two mounting nuts (5). Refer to Torque Specifications. 3. Install electrical connector (1) to APPS (6). 4. A Scan Tool may be used to learn electrical parameters. Go to the Miscellaneous menu, and then select ETC Learn. 5. If the previous step is not performed, a Diagnostic Trouble Code (DTC) will be set. 6. If necessary, use a scan tool to erase any Diagnostic Trouble Codes (DTCs) from PCM. 7. Before starting engine, operate accelerator pedal to check for any binding. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4118 Accelerator Pedal Position Sensor: Diagrams Connector - (HEADLAMP AND DASH) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (HEADLAMP AND DASH) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (6) is attached to the accelerator pedal assembly (4) under the instrument panel. The APPS is used only with the 5.7L V-8 engine. The APPS is part of the pedal assembly and is a non-serviceable part and the pedal assembly has to be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 4121 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) is a linear potentiometer. It provides the Powertrain Control Module (PCM) with a DC voltage signal proportional to the angle, or position of the accelerator pedal. The APPS signal is translated (along with other sensors) to place the throttle plate (within the throttle body) to a pre-determined position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal Air Filter Element: Service and Repair Air Cleaner - Removal REMOVAL - AIR FILTER ELEMENT - HEV 1. Remove the air cleaner trim covers (2) with a small screwdriver (1). 2. Remove the air clean cover fasteners (1). 3. Unclip the air cleaner cover latches (2). 4. Remove the air cleaner cover (3). 5. Remove the air filter element (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Air Cleaner - Removal > Page 4127 Air Filter Element: Service and Repair Air Cleaner - Installation INSTALLATION - AIR FILTER ELEMENT - HEV 1. Install a new filter element (1). 2. Install the air cleaner cover (3). 3. Install the air cleaner cover fasteners (1). 4. Secure the air cleaner cover latches (2). 5. Install the air cleaner trim covers (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Description and Operation Fuel: Description and Operation FUEL REQUIREMENTS Your engine is designed to meet all emissions regulations and provide excellent fuel economy and performance when using high quality unleaded "regular" gasoline having an octane rating of 87. The routine use of premium gasoline is not recommended. Under normal conditions the use of premium fuel will not provide a benefit over high quality regular gasolines and in some circumstances may result in poorer performance. Light spark knock at low engine speeds is not harmful to your engine. However, continued heavy spark knock at high speeds can cause damage and immediate service is required. Engine damage resulting from operation with a heavy spark knock may not be covered by the new vehicle warranty. Poor quality gasoline can cause problems such as hard starting, stalling and hesitations. If you experience these symptoms, try another brand of gasoline before considering service for the vehicle. Over 40 auto manufacturers world-wide have issued and endorsed consistent gasoline specifications (the Worldwide Fuel Charter, WWFC) to define fuel properties necessary to deliver enhanced emissions, performance and durability for your vehicle. We recommend the use of gasolines that meet the WWFC specifications if they are available. REFORMULATED GASOLINE Many areas of the country require the use of cleaner burning gasoline referred to as "reformulated" gasoline. Reformulated gasoline contain oxygenates, and are specifically blended to reduce vehicle emissions and improve air quality. We strongly support the use of reformulated gasoline. Properly blended reformulated gasoline will provide excellent performance and durability for the engine and fuel system components. GASOLINE/OXYGENATE BLENDS Some fuel suppliers blend unleaded gasoline with oxygenates such as 10% ethanol, MTBE, and ETBE. Oxygenates are required in some areas of the country during the winter months to reduce carbon monoxide emissions. Fuels blended with these oxygenates may be used in your vehicle. CAUTION: DO NOT use gasoline containing METHANOL. Gasoline containing methanol may damage critical fuel system components. MMT IN GASOLINE MMT is a manganese-containing metallic additive that is blended into some gasoline to increase octane. Gasoline blended with MMT provide no performance advantage beyond gasoline of the same octane number without MMT. Gasoline blended with MMT reduce spark plug life and reduce emission system performance in some vehicles. We recommend that gasolines free of MMT be used in your vehicle. The MMT content of gasoline may not be indicated on the gasoline pump; therefore, you should ask your gasoline retailer whether or not his/her gasoline contains MMT. It is even more important to look for gasoline without MMT in Canada because MMT can be used at levels higher than allowed in the United States. MMT is prohibited in Federal and California reformulated gasoline. SULFUR IN GASOLINE If you live in the northeast United States, your vehicle may have been designed to meet California low emission standards with Cleaner-Burning California reformulated gasoline with low sulfur. If such fuels are not available in states adopting California emission standards, your vehicles will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be adversely affected. Gasoline sold outside of California is permitted to have higher sulfur levels which may affect the performance of the vehicle's catalytic converter. This may cause the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light to illuminate. We recommend that you try a different brand of unleaded gasoline having lower sulfur to determine if the problem is fuel related prior to returning your vehicle to an authorized dealer for service. CAUTION: If the Malfunction Indicator Lamp (MIL), Check Engine or Service Engine Soon light is flashing, immediate service is required; see on-board diagnostics system section. MATERIALS ADDED TO FUEL All gasoline sold in the United States and Canada are required to contain effective detergent additives. Use of additional detergents or other additives is not needed under normal conditions. FUEL SYSTEM CAUTIONS CAUTION: Follow these guidelines to maintain your vehicle's performance: - The use of leaded gas is prohibited by Federal law. Using leaded gasoline can impair engine performance, damage the emission control system, Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Description and Operation > Page 4131 and could result in loss of warranty coverage. - An out-of-tune engine, or certain fuel or ignition malfunctions, can cause the catalytic converter to overheat. If you notice a pungent burning odor or some light smoke, your engine may be out of tune or malfunctioning and may require immediate service. Contact your dealer for service assistance. - When pulling a heavy load or driving a fully loaded vehicle when the humidity is low and the temperature is high, use a premium unleaded fuel to help prevent spark knock. If spark knock persists, lighten the load, or engine piston damage may result. - The use of fuel additives which are now being sold as octane enhancers is not recommended. Most of these products contain high concentrations of methanol. Fuel system damage or vehicle performance problems resulting from the use of such fuels or additives is not the responsibility of Chrysler Corporation and may not be covered under the new vehicle warranty. NOTE: Intentional tampering with emissions control systems can result in civil penalties being assessed against you. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Description Fuel Filler Cap: Description and Operation Description DESCRIPTION The plastic fuel fill cap is threaded/quarter turn onto the end of the fuel filler tube. It's purpose is to retain vapors and fuel in the fuel tank. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Description > Page 4136 Fuel Filler Cap: Description and Operation Operation OPERATION The loss of any fuel vapor out of fuel filler tube is prevented by the use of pressure-vacuum fuel fill cap. Relief valves inside the cap will release fuel tank pressure at predetermined pressures. Fuel tank vacuum will also be released at predetermined values. This cap must be replaced by a similar unit if replacement is necessary. This is in order for the system to remain effective. CAUTION: Remove fill cap before servicing any fuel system component to relieve tank pressure. If the cap is left loose, a Diagnostic Trouble Code (DTC) may be set. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation > Page 4137 Fuel Filler Cap: Service and Repair REMOVAL/INSTALLATION If replacement of the 1/4 turn fuel tank filler tube cap is necessary, it must be replaced with an identical cap to be sure of correct system operation. CAUTION: Remove the fuel tank filler tube cap to relieve fuel tank pressure. The cap must be removed prior to disconnecting any fuel system component or before draining the fuel tank. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator > Component Information > Description and Operation > Gas Cap Indicator - Description Fuel Filler Cap Warning Indicator: Description and Operation Gas Cap Indicator - Description DESCRIPTION A gas cap indicator is standard equipment on all instrument clusters. The gas cap indication appears within the odometer Vacuum Fluorescent Display (VFD) unit. The gas cap indicator consists of a textual GASCAP message which appears in place of the odometer/trip odometer information in the display. The odometer VFD is soldered onto the cluster electronic circuit board, and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The gas cap textual message appears in the same blue-green color and at the same lighting level as the odometer/trip odometer information when illuminated by the instrument cluster electronic circuit board. The gas cap indicator is serviced as a unit with the VFD in the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap Warning Indicator > Component Information > Description and Operation > Gas Cap Indicator - Description > Page 4142 Fuel Filler Cap Warning Indicator: Description and Operation Gas Cap Indicator - Operation OPERATION The gas cap indicator gives an indication to the vehicle operator when there is a gross leak detected in the on board fuel vapor recovery system. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The gas cap indicator function of the odometer Vacuum Fluorescent Display (VFD) unit is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the VFD gas cap indication is always off when the ignition switch is in any position except ON or START. The instrument cluster turns on the gas cap indicator for the following reasons: - Gas Cap Indicator Lamp-On Message - Each time the cluster receives an electronic gas cap indicator lamp-on message from the PCM indicating there is a gross leak in the vapor recovery system, the gas cap indicator illuminates. If the ignition switch is in the ON position and the vehicle is not moving when the message is received, the VFD repeatedly and sequentially cycles the gas cap indication in two second intervals with the odometer/trip odometer information and any other active textual warnings. If the vehicle is moving, or once the cluster of a non-moving vehicle receives an electronic vehicle speed message from the PCM indicating a speed greater than zero, the warning sequence consists of three complete display cycles with an audible single chime tone accompanying each cycle, then revert to only the visual gas cap indication and odometer/trip odometer display cycling until the cluster receives a message indicating there is no gross leak in the vapor recovery system, or until the ignition switch turns to the off position, whichever occurs first. The VFD can be reverted to the odometer display and any currently displayed textual messages suspended by momentarily depressing and releasing the odometer/trip odometer reset switch button on the front of the cluster. The PCM continually monitors the on board vapor recovery system to determine whether there are air leaks in the system. The PCM then sends the proper electronic messages to the instrument cluster, also known as the Cab Compartment Node (CCN). If the CCN turns on the gas cap indicator due to a monitored gross leak in the vapor recovery system, it may indicate that the gas cap has been removed or is improperly installed. Use a diagnostic scan tool for proper diagnosis of the on board vapor recovery system, the PCM, the CCN, the CAN data bus or the electronic communication related to gas cap indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair FUEL SYSTEM PRESSURE RELEASE - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions Use the following procedure if the fuel injector rail is, or is not equipped with a fuel pressure test port. 1. Remove the fuel fill cap. 2. Remove the fuel pump relay or the fuel pump speed relay from the Power Distribution Center (PDC) (1), refer to the label on the underside of the PDC cover for relay locations or See: Maintenance/Fuses and Circuit Breakers/Fuse/Locations/Fuse Panel 3. Start and run the engine until it stalls. 4. Attempt restarting the engine until it will no longer run. 5. Turn the ignition key to the OFF position. 6. Disconnect the 12 volt battery system ground isolation connector (1). 7. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down NOTE: Excessive fuel spillage onto the gaskets can cause gaskets to expand and dislodge from gasket groove. 8. Place a rag or towel around the fuel line quick-connect fitting at the fuel rail to prevent residual fuel spray or spillage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Page 4147 9. Disconnect the fuel supply line quick connect fitting at the fuel rail (1) and plug the fuel supply line with a shipping cap See: Fuel Line Coupler/Service and Repair 10. Return the fuel pump relay or the fuel pump speed relay to the PDC. NOTE: One or more Diagnostic Trouble Code(s) (DTC) may have been stored in the PCM memory due to the fuel pump relay removal. A diagnostic scan tool must be used to erase a DTC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications Fuel Injector: Specifications Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (5.7L) > Page 4153 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (5.7L) > Page 4154 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (5.7L) > Page 4155 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (5.7L) > Page 4156 Fuel Injector: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (5.7L) > Page 4157 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (5.7L) > Page 4158 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (5.7L) > Page 4159 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (5.7L) > Page 4160 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (5.7L) > Page 4161 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (5.7L) > Page 4162 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Locations > Fuel Injector 1 (5.7L) > Page 4163 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (Engine) 2 Way Fuel Injector: Diagrams Fuel Injector 1 (Engine) 2 Way Connector - (ENGINE) 2 WAY INJECTOR-FUEL 1 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (Engine) 2 Way > Page 4166 Fuel Injector: Diagrams Fuel Injector 2 (Engine) 2 Way Connector - (ENGINE) 2 WAY INJECTOR-FUEL 2 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (Engine) 2 Way > Page 4167 Fuel Injector: Diagrams Fuel Injector 3 (Engine) 2 Way Connector - (ENGINE) 2 WAY INJECTOR-FUEL 3 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (Engine) 2 Way > Page 4168 Fuel Injector: Diagrams Fuel Injector 4 (Engine) 2 Way Connector - (ENGINE) 2 WAY INJECTOR-FUEL 4 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (Engine) 2 Way > Page 4169 Fuel Injector: Diagrams Fuel Injector 1 (Engine) 2 Way Connector - (ENGINE) 2 WAY INJECTOR-FUEL 1 - (ENGINE) 2 WAY Fuel Injector 2 (Engine) 2 Way Connector - (ENGINE) 2 WAY INJECTOR-FUEL 2 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (Engine) 2 Way > Page 4170 Fuel Injector 3 (Engine) 2 Way Connector - (ENGINE) 2 WAY INJECTOR-FUEL 3 - (ENGINE) 2 WAY Fuel Injector 4 (Engine) 2 Way Connector - (ENGINE) 2 WAY INJECTOR-FUEL 4 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (Engine) 2 Way > Page 4171 Fuel Injector 5 (Engine) 2 Way Connector - (ENGINE) 2 WAY INJECTOR-FUEL 5 - (ENGINE) 2 WAY Fuel Injector 6 (Engine) 2 Way Connector - (ENGINE) 2 WAY INJECTOR-FUEL 6 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (Engine) 2 Way > Page 4172 Fuel Injector 7 (Engine) 2 Way Connector - (ENGINE) 2 WAY INJECTOR-FUEL 7 - (ENGINE) 2 WAY Fuel Injector 8 (Engine) 2 Way Connector - (ENGINE) 2 WAY INJECTOR-FUEL 8 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector 1 (Engine) 2 Way > Page 4173 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Description Fuel Injector: Description and Operation Description DESCRIPTION An individual fuel injector (1) is used for each individual cylinder. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Description and Operation > Description > Page 4176 Fuel Injector: Description and Operation Operation OPERATION The top (fuel entry) end of the injector (3) is attached into an opening on the fuel rail. The fuel injectors are electrical solenoids. The injector contains a pintle that closes off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel is under high pressure, a fine spray is developed in the shape of a pencil stream. The spraying action atomizes the fuel, adding it to the air entering the combustion chamber. The nozzle (outlet) ends of the injectors (2) are positioned into openings in the intake manifold just above the intake valve ports of the cylinder head. The engine wiring harness connector for each fuel injector is equipped with an attached numerical tag (INJ 1, INJ 2 etc.). This is used to identify each fuel injector. The injectors are energized individually in a sequential order by the Powertrain Control Module (PCM). The PCM will adjust injector pulse width by switching the ground path to each individual injector on and off. Injector pulse width is the period of time that the injector is energized. The PCM will adjust injector pulse width based on various inputs it receives. Battery voltage is supplied to the injectors through the ASD relay. The PCM determines injector pulse width based on various inputs. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal Fuel Injector: Service and Repair Fuel Injector - Removal REMOVAL - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Remove the fuel rail assembly See: Fuel Rail/Service and Repair/Fuel Rail - Removal 3. Using suitable pliers (1), remove the fuel injector retaining clip (2). 4. Remove the fuel injector (3) from the fuel rail (4) using a side to side motion while pulling the injector out of the fuel rail assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector - Removal > Page 4179 Fuel Injector: Service and Repair Fuel Injector - Installation INSTALLATION - HEV NOTE: If the same fuel injector is to be reinstalled, install new O-rings. NOTE: Apply a small amount of clean engine oil to each injector O-ring. This will aid in the installation. 1. Install the fuel injector (3) into the fuel rail (4) using a side to side motion while pushing injector into the fuel rail assembly. 2. Using suitable pliers (1), install the fuel injector retaining clip (2). 3. Install the fuel rail assembly See: Fuel Rail/Service and Repair/Fuel Rail - Installation 4. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 5. Start engine and check for fuel leaks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation DESCRIPTION Different types of quick-connect fittings are used to attach various fuel system components, lines and tubes. These are: a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require the use of a tool for disconnection and removal. See: Service and Repair CAUTION: The interior components (O-rings, clips) of quick-connect fittings are not serviced separately, but new plastic spacers are available for some types. If service parts are not available, do not attempt to repair the damaged fitting or fuel line (tube). If repair is necessary, replace the complete fuel line (tube) assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 4183 Fuel Line Coupler: Service and Repair QUICK-CONNECT FITTINGS Different types of quick-connect fittings are used to attach the various fuel system components, lines and tubes. These are: a single-button type, a two-button type, a pinch type, a single-tab type, a two-tab type or a plastic retainer ring type. Some are equipped with safety latch clips. Some may require the use of a special tool for disconnection and removal. DISCONNECTING WARNING: The fuel system is under a constant pressure (even with engine off). Before servicing any fuel system hose, fitting or line, fuel system pressure must be released. See: Fuel Filter/Fuel Pressure Release/Service and Repair CAUTION: Before separating a quick-connect fitting, pay attention to what type of fitting is being used by referring to Quick-Connect Fitting Removal. This will prevent unnecessary fitting or fitting latch breakage. CAUTION: The interior components (O-rings, clips) of quick-connect fittings are not serviced separately, but new plastic spacers and latches are available for some types. If service parts are not available, do not attempt to repair the damaged fitting or fuel line (tube). If repair is necessary, replace the complete fuel line (tube) assembly. 1. Perform fuel pressure release procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect negative battery cable from battery. 3. Clean fitting of any foreign material before disassembly. 4. Single-Button Type Fitting: This type of fitting is equipped with a single push-button (2) located on the quick-connect fitting. 5. The push-button is attached to two internal latches (1). To disconnect, press on push-button with your thumb and unlatch fitting from fuel line. Special tools are not required for disconnection. DO NOT ATTEMPT TO PRY OR PULL UP ON PUSH-BUTTON. LATCHES WILL BE BROKEN. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 4184 6. Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair 7. Disconnect negative battery cable from battery. 8. Clean fitting of any foreign material before disassembly. 9. 2-Button Type Fitting: This type of fitting (1) is equipped with a push-button located on each side of quick-connect fitting (2). Press on both buttons simultaneously for removal. Special tools are not required for disconnection. 10. Pinch-Type Fitting: This fitting (1) is equipped with two finger tabs (2). Pinch both tabs together while removing fitting. Special tools are not required for disconnection. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 4185 11. Single-Tab Type Fitting: This type of fitting (3) is equipped with a single pull tab (1). The tab is removable. After tab is removed, quick-connect fitting can be separated from fuel system component. Special tools are not required for disconnection. 12. Press release tab on side of fitting to release pull tab (1). If release tab is not pressed prior to releasing pull tab, pull tab will be damaged. 13. While pressing release tab on side of fitting, use screwdriver (2) to pry up pull tab. 14. Raise pull tab until it separates from quick-connect fitting. 15. Two-Tab Type Fitting: This type of fitting (2) is equipped with tabs located on both sides of fitting (1). The tabs are supplied for disconnecting quick-connect fitting from component being serviced. a. To disconnect quick-connect fitting, squeeze plastic retainer tabs (1) against sides of quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. b. Pull fitting from fuel system component being serviced. c. The plastic retainer will remain on component being serviced after fitting is disconnected. The O-rings and spacer will remain in quick-connect fitting connector body. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 4186 16. Plastic Retainer Ring Type Fitting: This type of fitting can be identified by the use of a full-round plastic retainer ring (4) usually black in color. a. To release fuel system component from quick-connect fitting, firmly push fitting towards component being serviced while firmly pushing plastic retainer ring into fitting (6). With plastic ring depressed, pull fitting from component. The plastic retainer ring must be pressed squarely into fitting body. If this retainer is cocked during removal, it may be difficult to disconnect fitting. Use an open-end wrench on shoulder of plastic retainer ring to aid in disconnection. b. After disconnection, plastic retainer ring will remain with quick-connect fitting connector body. c. Inspect fitting connector body, plastic retainer ring and fuel system component for damage. Replace as necessary. 17. Latch Clips Type 1: Depending on vehicle model and engine, 2 different types of safety latch clips are used. Type-1 (4) is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/fuel rail connection, or to join fuel lines together. 18. Pry up on latch clip with a screwdriver (3). 19. Slide latch clip toward fuel rail while lifting with screwdriver. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 4187 20. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1). Use tool to release locking fingers in end of line. 21. With special tool still inserted, pull fuel line from fuel rail. 22. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 23. Disconnect quick-connect fitting from fuel system component being serviced. 24. Latch Clips Type 2: Depending on vehicle model and engine, 2 different types of safety latch clips are used. Type-1 is tethered to fuel line and type-2 is not. A special tool will be necessary to disconnect fuel line after latch clip is removed. The latch clip may be used on certain fuel line/fuel rail connection, or to join fuel lines together. 25. Type 2: Separate and unlatch small arms on end of clip and swing away from fuel line. 26. Slide latch clip toward fuel rail while lifting with screwdriver. 27. Insert special fuel line removal tool (Snap-On number FIH 9055-1 or equivalent) into fuel line (1). Use tool to release locking fingers in end of line. 28. With special tool still inserted, pull fuel line from fuel rail. 29. After disconnection, locking fingers will remain within quick-connect fitting at end of fuel line. 30. Disconnect quick-connect fitting from fuel system component being serviced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation > Page 4188 31. Wing Type: A special tool is not necessary to disconnect this type of fitting (2). This line is used on different fuel and emission components. The graphic shows the fitting used on an EVAP canister. 32. Use two fingers to push on fitting wings (2) 33. Pull and disconnect fitting while holding wings. 34. After disconnection, locking fingers will remain within quick-connect fitting. CONNECTING 1. Inspect quick-connect fitting body and fuel system component for damage. Replace as necessary. 2. Prior to connecting quick-connect fitting to component being serviced, check condition of fitting and component. Clean parts with a lint-free cloth. Lubricate with clean engine oil. 3. Insert quick-connect fitting into fuel tube or fuel system component until built-on stop on fuel tube or component rests against back of fitting. 4. Continue pushing until a click is felt. 5. Single-tab type fitting: Push new tab down until it locks into place in quick-connect fitting. 6. Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). 7. Latch Clip Equipped: Install latch clip (snaps into position). If latch clip will not fit, this indicates fuel line is not properly installed to fuel rail (or other fuel line). Recheck fuel line connection. 8. Connect negative cable to battery. 9. Start engine and check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation Fuel Pressure Sensor/Switch: Description and Operation DESCRIPTION - HEV The fuel tank pressure sensor provides the PCM with information on vapor pressure inside the fuel tank. The sensor is a diaphragm-type pressure sensor and varies its voltage output depending on fuel tank pressure. When the fuel tank isolation valve is activated (closed), preventing fuel vapors from leaving the tank, the PCM will monitor the fuel tank pressure sensor to prevent pressure from increasing or decreasing to an unsafe level. Excessive fuel tank pressure could cause fuel vapors to vent out the fuel cap or damage system components while insufficient fuel tank pressure (vacuum) caused by lack of air entering the tank to take the place of consumed fuel could lead to collapsed tank, lines or loss of fuel pressure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor - Removal REMOVAL - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the fuel system pressure release procedure See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 3. Disconnect the 12 volt battery system ground isolation connector (1). 4. Raise and support the vehicle. 5. Disconnect the fuel fill hose (1) at the rear of the fuel tank. 6. Disconnect the fuel fill vapor line quick-connect fitting (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 4194 7. Disconnect the electrical connector at the EVAP System Integrity Monitor (ESIM) switch (2). 8. Disconnect the fuel tank isolation valve electrical connector (2) at the EVAP canister mounting bracket. 9. Disconnect the fuel tank isolation valve vapor line quick-connect fitting (1) to the purge solenoid tubing connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 4195 10. Support the fuel tank with a suitable hydraulic jack. 11. Remove the two fuel tank support strap retaining bolts (2) and position both support straps (3) aside. 12. Carefully lower the fuel tank (1) a few inches. 13. Disconnect the fuel pressure sensor electrical connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 4196 14. Thoroughly clean the area around the fuel pressure sensor. 15. Remove the fuel pressure sensor from the fuel tank (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 4197 Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor - Installation INSTALLATION - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Install the fuel pressure sensor (1) into the fuel tank. 2. Connect the fuel pressure sensor electrical connector (1). 3. Raise the fuel tank until snug to the body. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 4198 4. Position both fuel tank support straps (3), install the retaining bolts (2) and tighten to 40 Nm (30 ft. lbs.). 5. Remove the hydraulic jack. 6. Connect the fuel tank isolation valve vapor line quick-connect fitting (1) to the purge solenoid tubing connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 4199 7. Connect the fuel tank isolation valve electrical connector (2) at the EVAP canister mounting bracket. 8. Connect the electrical connector at the EVAP System Integrity Monitor (ESIM) switch (2). 9. Connect the fuel fill hose (1) at the rear of the fuel tank. 10. Connect the fuel fill vapor line quick-connect fitting (2). 11. Lower the vehicle. 12. Connect the 12 volt battery system ground isolation connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 4200 13. Connect the fuel line quick connect fitting to the fuel rail (1) See: Fuel Line Coupler/Service and Repair 14. Install the fuel fill cap. 15. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 16. Start the engine and check for leaks at all fuel tank connections. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications FUEL SYSTEM PRESSURE The correct fuel pressure for this vehicle is 58 psi +/- 2 psi Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 4205 Fuel Pressure: Testing and Inspection FUEL PRESSURE LEAK DOWN For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. WARNING: Follow these safety precautions to reduce the risk of fire and serious possible serious or fatal injury when performing this test procedure. Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks. - Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system. - Relieve fuel system pressure before servicing fuel system components. Use extreme caution when connecting and disconnecting fuel lines. - Considerable fuel leakage may occur when servicing the fuel system. Wear protective eye wear and clothing to protect from fuel splash, and take suitable fuel containment measures. - Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete. - Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. CHECK FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Visually and physically inspect the fuel delivery system for external leaks and damage. Is the system leaking or damaged? Yes - Repair / replace as necessary. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test No - Go To 2 2. INSTALL APPROPRIATE FUEL LINE ADAPTERS / FITTING FROM GAS AND DIESEL FUEL PRESSURE/DECAY TESTER 8978A 1. Turn the ignition off. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 4206 WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 2. Disconnect the frame rail fuel supply line connector between the fuel supply line and the fuel rail. 3. Install the appropriate Fuel Line Adapters / Fitting from Gas and Diesel Fuel Pressure/Decay Tester 8978A. Proceed - Go To 3 3. INSTALL FUEL PRESSURE GAUGE ASSEMBLY WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Connect Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978A-1 (1) and Fuel Outlet Hose (2) to the Fuel Line Adapters / Fitting. 2. Connect Drain Extension Hose 535680 (3) to the Fuel Pressure Gauge Assembly Drain Hose (5). 3. Connect the Reservoir Assembly 534960 (4) to the Drain Extension Hose 535680 (3). WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place Reservoir Assembly 534960 (4) on the floor and out of the way so that it is not a trip hazard. Proceed - Go To 4 4. CHECK FUEL PRESSURE WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Perform the following procedure to purge air from the system: Open the Fuel System Isolation Valve (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 4207 - Close the Flow Test Valve (2). - Ignition on, engine not running. - With the scan tool, actuate the fuel pump. - Open the Flow Test Valve (1) for 10 seconds, then close the Valve. - CAUTION: Stop All Actuations. - Turn the ignition off. - Disconnect, empty and then reconnect the Reservoir Assembly. 2. Turn the ignition on, wait five seconds, turn the ignition off and then wait 1 minute before proceeding. 3. Read the Fuel Pressure Gauge (3) and record the reading. Non SRT-4 fuel pressure specification is 407 Kpa +/- 34 Kpa (59 psi +/- 5 psi). SRT-4 fuel pressure specification is 552 Kpa +/- 34 Kpa (80 psi +/- 5 psi). Is the fuel pressure within specifications? Yes - Go To 5 No - Perform the Checking The Fuel Delivery System diagnostic procedure as directed. 5. CHECK FUEL DELIVERY SYSTEM FOR LEAK DOWN WARNING: The fuel system is under a constant pressure (even with the engine off). Before testing or servicing any fuel system hose, fitting, or line, the fuel system pressure must be released. Failure to follow these instructions can result in possible serious or fatal injury. 1. Close the Fuel System Isolation Valve (1) and then wait five minutes before proceeding. 2. Read the Fuel Inlet (2) and Fuel Outlet (3) Pressure Gauges. The pressure should not drop more than 10 psi on either gauge. Does the fuel pressure drop more than 10 psi? Yes - On Fuel Inlet Gauge (1) - Replace the fuel pump module. - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test Yes - On Fuel Outlet Gauge (2) - Replace the leaking fuel injector(s). - Perform the PCM VERIFICATION TEST. See: Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Powertrain Verification Test. No - If directed here by another test, return to that test. Otherwise, test complete. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Ballast Resistor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Ballast Resistor > Component Information > Locations > Page 4211 Fuel Pump Ballast Resistor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 2 WAY RESISTOR-FUEL PUMP (HEV) - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Fuel Pump Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay (In PDC) Fuel Pump Relay: Diagrams Fuel Pump Relay (In PDC) Connector (IN PDC) RELAY-FUEL PUMP (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay (In PDC) > Page 4217 Fuel Pump Relay: Diagrams Fuel Pump Speed Relay (HEV) (In PDC) Connector (HEV) - (IN PDC) RELAY-FUEL PUMP SPEED (HEV) - (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Description and Operation > Description Fuel Pump Relay: Description and Operation Description DESCRIPTION The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the power distribution center cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Description and Operation > Description > Page 4220 Fuel Pump Relay: Description and Operation Operation OPERATION The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shut-down the ground circuit to the fuel pump relay in approximately 1-3 seconds unless the engine is operating or the starter motor is engaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Service and Repair > Removal Fuel Pump Relay: Service and Repair Removal REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on power distribution center cover for relay location. 1. Remove power distribution center cover. 2. Remove relay from power distribution center. 3. Check condition of relay terminals and power distribution center connector terminals for damage or corrosion. Repair or replace as necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the power distribution center connector). Repair or replace as necessary before installing relay. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Service and Repair > Removal > Page 4223 Fuel Pump Relay: Service and Repair Installation INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on power distribution center cover for relay location. 1. Install relay to power distribution center. 2. Install cover to power distribution center. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Description Fuel Rail: Description and Operation Description DESCRIPTION The fuel injector rail is used to mount the fuel injectors to the engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Description > Page 4228 Fuel Rail: Description and Operation Operation OPERATION High pressure from the fuel pump is routed to the fuel rail. The fuel rail then supplies the necessary fuel to each individual fuel injector. A quick-connect fitting with a safety latch clip is used to attach the fuel line to the fuel rail. The fuel rail is not repairable. CAUTION: The left and right sections of the fuel rail are connected with either a flexible connecting hose, or joints. Do not attempt to separate the rail halves at these connecting hose or joints. Due to the design of the connecting hose or joint, it does not use any clamps. Never attempt to install a clamping device of any kind to the hose or joint. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connecting hose or joint. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal Fuel Rail: Service and Repair Fuel Rail - Removal 5.7L WARNING: The fuel system is under constant pressure even with engine off. Before servicing fuel rail, fuel system pressure must be released. 1. Perform the fuel pressure release procedure See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Remove the negative battery cable (1). 3. Loosen the clean air hose clamps (2) and remove the clean air hose. 4. Remove the resonator assembly See: Air Cleaner Housing/Air Filter Element/Service and Repair/Air Cleaner - Removal on the 5.7L HEV, remove the air cleaner assembly See: Air Cleaner Housing/Service and Repair/Air Cleaner Body Removal CAUTION: The left and right fuel rails are replaced as an assembly. Do not attempt to separate the fuel rail halves at the connector tube. Due to the design of the connector tube, it does not use any clamps. Never attempt to install a clamping device of any kind to the connector tube. When removing the fuel rail assembly for any reason, be careful not to bend or kink the connector tube. NOTE: The factory fuel injection electrical harness is numerically tagged (INJ 1, INJ 2, etc.) for injector position identification. If the electrical harness is not tagged, note the injector position before electrical harness removal. 5. Disconnect the electrical connectors at all eight fuel injectors. Push the red colored slider away from the injector (1) while pushing slider, depress tab (2) and remove the electrical connector (3) from the injector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal > Page 4231 6. Disconnect the brake booster hose (1) and the vapor purge hose (2) and position aside to gain access to the fuel rail. 7. Disconnect the PCV hose (1) and position aside to gain access to the fuel rail. 8. Disconnect the fuel line quick connect fitting (2) at the fuel rail See: Fuel Line Coupler/Service and Repair 9. Disconnect the make up air hose (3) and position aside to gain access to the fuel rail. 10. Remove the four fuel rail mounting bolts (4) from both the left and right fuel rails. 11. Using a side to side motion, gently rock the left fuel rail while pulling up until all four left side fuel injectors just start to clear the machined holes in the intake manifold. 12. Using a side to side motion, gently rock the right fuel rail while pulling up until all four right side fuel injectors just start to clear the machined holes in the intake manifold. NOTE: Make sure the O-rings are still attached to the fuel injectors during removal. 13. Remove the left and right fuel rails (with injectors attached) as an assembly from the engine. NOTE: If the same fuel injectors are to be reinstalled, install new O-rings. 14. If the fuel injectors are to be removed from the fuel rail See: Fuel Injector/Service and Repair/Fuel Injector - Removal Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal > Page 4232 Fuel Rail: Service and Repair Fuel Rail - Installation 5.7L 1. If the fuel injectors are to be installed into the fuel rail See: Fuel Injector/Service and Repair/Fuel Injector - Installation 2. Clean out the fuel injector machined holes in the intake manifold. NOTE: If the same fuel injectors are to be reinstalled, install new O-rings. 3. Apply a small amount of engine oil to each fuel injector O-ring. This will help in the fuel rail installation. 4. Position the fuel rail assembly while aligning the injectors into the machined holes in the intake manifold. 5. Guide each injector into the intake manifold using care not to tear the injector O-rings. 6. Using a side to side motion, gently rock the left fuel rail while pushing down until all four left side fuel injectors have completely seated into the machined holes in the intake manifold. 7. Using a side to side motion, gently rock the right fuel rail while pushing down until all four right side fuel injectors have completely seated into the machined holes in the intake manifold. 8. Install the four fuel rail mounting bolts (4) and tighten to 8 Nm (71 in. lbs.). 9. Connect the make up air hose (3). 10. Connect the fuel line quick connect fitting to the fuel rail (2) See: Fuel Line Coupler/Service and Repair 11. Connect the PCV hose (1). 12. Connect the brake booster hose (1) and the vapor purge hose (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Service and Repair > Fuel Rail - Removal > Page 4233 13. Connect the electrical connectors at all eight fuel injectors. Push the connector onto the injector (1) and then push and lock the red colored slider (2). Verify the connector is locked to the injector by lightly tugging on the connector. 14. Install the resonator assembly See: Air Cleaner Housing/Air Filter Element/Service and Repair/Air Cleaner - Installation on the 5.7L HEV, install the air cleaner assembly See: Air Cleaner Housing/Service and Repair/Air Cleaner Body Installation 15. Install the clean air hose and securely tighten hose clamps (2). 16. Connect the negative battery cable (1). 17. Start the engine and check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation Fuel Supply Line: Description and Operation DESCRIPTION See: Fuel Line Coupler/Service and Repair WARNING: The fuel system may be under a constant pressure (even with the engine off). Before servicing any fuel system hoses, fittings, lines, or most components, fuel system pressure must be released. Refer to the fuel system pressure release procedure. See: Fuel Filter/Fuel Pressure Release/Service and Repair The lines/tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these lines/tubes/hoses, only those marked EFM/EFI may be used. If equipped: The hose clamps used to secure rubber hoses on fuel injected vehicles are of a special rolled edge construction. This construction is used to prevent the edge of the clamp from cutting into the hose. Only these rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause high-pressure fuel leaks. Use new original equipment type hose clamps. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Filler Neck: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4246 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4247 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Filler Neck: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4253 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4254 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 4258 Fuel Gauge Sender: Diagrams Connector - (CHASSIS) 4 WAY MODULE-FUEL PUMP - (CHASSIS) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 4259 Fuel Gauge Sender: Description and Operation DESCRIPTION The fuel pump module assembly (4) is located on the top of the fuel tank (2). The module assembly (5) contains the following components: - An internal fuel filter - A separate fuel pick-up, or inlet filter (3) - A fuel pressure regulator (4) - An electric fuel pump (2) - A lock ring to retain pump module to tank - A soft gasket between tank flange and module - A fuel gauge sending unit (fuel level sensor) (1) - Fuel line connection (6) If the fuel gauge sending unit, electrical fuel pump, primary inlet filter, fuel filter or fuel pressure regulator require service, the fuel pump module must be replaced. Electric Fuel Pump The electric fuel pump is located inside of the fuel pump module. A 12 volt, permanent magnet, electric motor powers the fuel pump. The electric fuel pump is not a separate, serviceable component. Fuel Filters Two fuel filters are used. One is located at the bottom of the fuel pump module. The other is located inside the module. A separate frame mounted fuel filter is not used with any engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Locations > Page 4260 Both fuel filters are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator The fuel pressure regulator is located within fuel pump module. Fuel Gauge Sending Unit (Fuel level sensor) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Gauge Sender: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: The fuel system is under a constant pressure, even with the engine off. Before servicing the fuel pump module, the fuel system pressure must be released. 1. Perform the fuel system pressure release procedure See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Disconnect and isolate the negative battery cable. 3. Drain and remove the fuel tank See: Service and Repair/Removal and Replacement/Fuel Tank - Removal 4. Note the rotational position of the module before attempting removal. An indexing arrow is located on top of the module for this purpose. 5. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 6. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 7. Rotate the breaker bar counterclockwise to remove the lock ring. 8. Remove the lock ring. The module will spring up slightly when the lock ring is removed. 9. Remove the module from the fuel tank. Be careful not to bend the float arm during removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 4263 Fuel Gauge Sender: Service and Repair Fuel Pump Module - Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position the fuel pump module into the opening of the fuel tank. 2. Rotate the module until the embossed alignment arrow points to the center alignment mark. This step must be performed to prevent the float from contacting the side of the fuel tank. Also be sure the fuel fitting on top of the pump module is pointed to the left side of the vehicle. 3. Position the lock ring (5) over the top of the fuel pump module. 4. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 5. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 6. Tighten the lock ring (clockwise) until all seven notches have engaged. 7. Install the fuel tank See: Service and Repair/Removal and Replacement/Fuel Tank - Installation 8. Lower the vehicle. 9. Connect the fuel line quick connect fitting to the fuel rail (1)See: Fuel Line Coupler/Service and Repair 10. Connect the negative battery cable. 11. Install the fuel fill cap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Tank Vent: Customer Interest Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4272 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4273 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off Fuel Tank Vent: All Technical Service Bulletins Fuel System - Difficult Fuel Fill/Nozzle Shuts Off NUMBER: 14-001-09 REV. A GROUP: Fuel DATE: September 1, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly MODELS: 2004-2008 (CS) Pacifica 2009 (DS) Ram Truck (1500) 2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up) 2005 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2005 - 2009 (ND) Dakota 2009 (JC) Journey 2007 - 2009 (JK) Wrangler 2007 - 2009 (J1) Sebring (China CKD) 2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger 2006 - 2009 (K1) Cherokee (CKD) 2007 - 2009 (KA) Nitro 2008 - 2009 (KK) Liberty 2008 - 2009 (KK) Cherokee (International Markets) 2005-2007 (KJ) Liberty 2005 - 2007 (KJ) Cherokee (International Markets) 2005 - 2009 (LE) 300C/300C Touring (International Markets) 2005 - 2009 (LX) 300/Magnum/Charger 2007 (L2) 300 (China) 2008 - 2009 (LC) Challenger 2004 - 2009 (PT) Chrysler PT Cruiser 2007 (R2) Caravan/Voyager(CKD) 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2003 - 2007 (RS) Town & Country/Caravan/Voyager Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4279 2008 - 2009 (RI) Town & Country/Grand Caravan 2008 - 2009 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2006 (TJ) Wrangler 2005 - 2009 (WH) Grand Cherokee (International Markets) 2005 - 2009 (WK) Grand Cherokee 2006 - 2009 (XH) Commander (International Markets) 2006 - 2009 (XK) Commander NOTE: This bulletin applies to all vehicles equipped with a gasoline engine. DISCUSSION: Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle shuts off repeatedly while trying to fill vehicle. This customer complaint can occur due to a number of different causes. The fuel tank is the least likely cause of this condition. The following Diagnostic procedure can be used to diagnose the issues. DIAGNOSIS: 1. Is the vehicle a LX/LE/LC/L2? a. Yes >> proceed to Step # 2 b. No >> proceed to Step # 4 2. Idle the vehicle 60 to 90 seconds upon stopping. 3. Does tank refill properly? a. No >> proceed to Step # 4 b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle to idle for this amount of time will let the fuel pump transfer fuel to the left side tank, opening the control valve and allowing normal fuel filling. 4. Disconnect the vapor recirculation tube at the fuel tank. 5. Attempt to refill fuel tank. 6. Does tank refill properly? a. Yes >> Proceed to Step # 7 b. No >> Proceed to Step # 11. 7. Reconnect the vapor recirculation tube at the fuel tank. 8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube. 9. Attempt to refill fuel tank. 10. Does tank refill properly? a. Yes >> Replace fuel filler tube. b. No >> Replace the vapor recirculation tube. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Vent > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Vent: > 14-001-09A > Sep > 09 > Fuel System - Difficult Fuel Fill/Nozzle Shuts Off > Page 4280 11. Disconnect the control valve to EVAP canister tube at the fuel tank. 12. Reconnect the vapor recirculation tube at the fuel tank. 13. Does tank refill properly? a. No >> Replace Fuel Tank. b. Yes >> Proceed to 14. Reconnect the control valve to EVAP canister tube at the fuel tank. 15. Disconnect the control valve to EVAP canister tube at the EVAP canister. 16. Attempt to refill fuel tank. 17. Does tank refill properly? a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent hose), or filter. Diagnose appropriately. b. No >> Replace the control valve to EVAP canister tube. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Auto Shut Down Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4284 Main Relay (Computer/Fuel System): Diagrams Connector (IN PDC) RELAY-AUTO SHUT DOWN (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay Description DESCRIPTION The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description > Page 4287 Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay - Operation PCM Output PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Removal REMOVAL The ASD relay is located in the engine compartment within the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal > Page 4290 Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Installation INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Fuel Pump Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay (In PDC) Fuel Pump Relay: Diagrams Fuel Pump Relay (In PDC) Connector (IN PDC) RELAY-FUEL PUMP (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Fuel Pump Relay (In PDC) > Page 4297 Fuel Pump Relay: Diagrams Fuel Pump Speed Relay (HEV) (In PDC) Connector (HEV) - (IN PDC) RELAY-FUEL PUMP SPEED (HEV) - (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Description Fuel Pump Relay: Description and Operation Description DESCRIPTION The 5-pin, 12-volt, fuel pump relay is located in the Power Distribution Center (PDC). Refer to the label on the power distribution center cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Description and Operation > Description > Page 4300 Fuel Pump Relay: Description and Operation Operation OPERATION The Powertrain Control Module (PCM) energizes the electric fuel pump through the fuel pump relay. The fuel pump relay is energized by first applying battery voltage to it when the ignition key is turned ON, and then applying a ground signal to the relay from the PCM. Whenever the ignition key is turned ON, the electric fuel pump will operate. But, the PCM will shut-down the ground circuit to the fuel pump relay in approximately 1-3 seconds unless the engine is operating or the starter motor is engaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Service and Repair > Removal Fuel Pump Relay: Service and Repair Removal REMOVAL The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on power distribution center cover for relay location. 1. Remove power distribution center cover. 2. Remove relay from power distribution center. 3. Check condition of relay terminals and power distribution center connector terminals for damage or corrosion. Repair or replace as necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the power distribution center connector). Repair or replace as necessary before installing relay. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Service and Repair > Removal > Page 4303 Fuel Pump Relay: Service and Repair Installation INSTALLATION The fuel pump relay is located in the Power Distribution Center (PDC). Refer to label on power distribution center cover for relay location. 1. Install relay to power distribution center. 2. Install cover to power distribution center. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Auto Shut Down Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4307 Main Relay (Computer/Fuel System): Diagrams Connector (IN PDC) RELAY-AUTO SHUT DOWN (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay Description DESCRIPTION The 5-pin, 12-volt, Automatic Shutdown (ASD) relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Description and Operation > Auto Shutdown Relay - Description > Page 4310 Main Relay (Computer/Fuel System): Description and Operation Auto Shutdown Relay - Operation PCM Output PCM OUTPUT The ASD relay supplies battery voltage (12+ volts) to the fuel injectors and ignition coil(s). With certain emissions packages it also supplies 12-volts to the oxygen sensor heating elements. The ground circuit for the coil within the ASD relay is controlled by the Powertrain Control Module (PCM). The PCM operates the ASD relay by switching its ground circuit on and off. The ASD relay will be shut-down, meaning the 12-volt power supply to the ASD relay will be de-activated by the PCM if: - The ignition key is left in the ON position. This is if the engine has not been running for approximately 1.8 seconds. - There is a crankshaft position sensor signal to the PCM that is lower than pre-determined values. ASD Sense - PCM Input ASD SENSE - PCM INPUT A 12 volt signal at this input indicates to the PCM that the ASD has been activated. The relay is used to connect the oxygen sensor heater element, ignition coil and fuel injectors to 12 volt + power supply. This input is used only to sense that the ASD relay is energized. If the Powertrain Control Module (PCM) does not see 12 volts at this input when the ASD should be activated, it will set a Diagnostic Trouble Code (DTC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Removal REMOVAL The ASD relay is located in the engine compartment within the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Remove PDC cover. 2. Remove relay from PDC. 3. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 4. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Service and Repair > Auto Shutdown Relay - Removal > Page 4313 Main Relay (Computer/Fuel System): Service and Repair Auto Shutdown Relay - Installation INSTALLATION The ASD relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Install relay to PDC. 2. Install cover to PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Locations > Page 4318 Accelerator Pedal Position Sensor: Diagrams Connector - (HEADLAMP AND DASH) 6 WAY SENSOR-ACCELERATOR PEDAL POSITION - (HEADLAMP AND DASH) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description Accelerator Pedal Position Sensor: Description and Operation Description DESCRIPTION The Accelerator Pedal Position Sensor (APPS) (6) is attached to the accelerator pedal assembly (4) under the instrument panel. The APPS is used only with the 5.7L V-8 engine. The APPS is part of the pedal assembly and is a non-serviceable part and the pedal assembly has to be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Accelerator Pedal Position Sensor > Component Information > Description and Operation > Description > Page 4321 Accelerator Pedal Position Sensor: Description and Operation Operation OPERATION The Accelerator Pedal Position Sensor (APPS) is a linear potentiometer. It provides the Powertrain Control Module (PCM) with a DC voltage signal proportional to the angle, or position of the accelerator pedal. The APPS signal is translated (along with other sensors) to place the throttle plate (within the throttle body) to a pre-determined position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation Fuel Pressure Sensor/Switch: Description and Operation DESCRIPTION - HEV The fuel tank pressure sensor provides the PCM with information on vapor pressure inside the fuel tank. The sensor is a diaphragm-type pressure sensor and varies its voltage output depending on fuel tank pressure. When the fuel tank isolation valve is activated (closed), preventing fuel vapors from leaving the tank, the PCM will monitor the fuel tank pressure sensor to prevent pressure from increasing or decreasing to an unsafe level. Excessive fuel tank pressure could cause fuel vapors to vent out the fuel cap or damage system components while insufficient fuel tank pressure (vacuum) caused by lack of air entering the tank to take the place of consumed fuel could lead to collapsed tank, lines or loss of fuel pressure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor - Removal REMOVAL - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform the fuel system pressure release procedure See: Fuel Filter/Fuel Pressure Release/Service and Repair 2. Perform the HEV high voltage power down procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 3. Disconnect the 12 volt battery system ground isolation connector (1). 4. Raise and support the vehicle. 5. Disconnect the fuel fill hose (1) at the rear of the fuel tank. 6. Disconnect the fuel fill vapor line quick-connect fitting (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 4327 7. Disconnect the electrical connector at the EVAP System Integrity Monitor (ESIM) switch (2). 8. Disconnect the fuel tank isolation valve electrical connector (2) at the EVAP canister mounting bracket. 9. Disconnect the fuel tank isolation valve vapor line quick-connect fitting (1) to the purge solenoid tubing connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 4328 10. Support the fuel tank with a suitable hydraulic jack. 11. Remove the two fuel tank support strap retaining bolts (2) and position both support straps (3) aside. 12. Carefully lower the fuel tank (1) a few inches. 13. Disconnect the fuel pressure sensor electrical connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 4329 14. Thoroughly clean the area around the fuel pressure sensor. 15. Remove the fuel pressure sensor from the fuel tank (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 4330 Fuel Pressure Sensor/Switch: Service and Repair Fuel Pressure Sensor - Installation INSTALLATION - HEV WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Install the fuel pressure sensor (1) into the fuel tank. 2. Connect the fuel pressure sensor electrical connector (1). 3. Raise the fuel tank until snug to the body. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 4331 4. Position both fuel tank support straps (3), install the retaining bolts (2) and tighten to 40 Nm (30 ft. lbs.). 5. Remove the hydraulic jack. 6. Connect the fuel tank isolation valve vapor line quick-connect fitting (1) to the purge solenoid tubing connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 4332 7. Connect the fuel tank isolation valve electrical connector (2) at the EVAP canister mounting bracket. 8. Connect the electrical connector at the EVAP System Integrity Monitor (ESIM) switch (2). 9. Connect the fuel fill hose (1) at the rear of the fuel tank. 10. Connect the fuel fill vapor line quick-connect fitting (2). 11. Lower the vehicle. 12. Connect the 12 volt battery system ground isolation connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Service and Repair > Fuel Pressure Sensor - Removal > Page 4333 13. Connect the fuel line quick connect fitting to the fuel rail (1) See: Fuel Line Coupler/Service and Repair 14. Install the fuel fill cap. 15. Perform the HEV high voltage power up procedure See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 16. Start the engine and check for leaks at all fuel tank connections. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 4337 Throttle Body: Diagrams Connector (5.7L) - (ENGINE) 6 WAY THROTTLE BODY (5.7L) - (ENGINE) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Locations > Page 4338 Throttle Body: Description and Operation DESCRIPTION The throttle body is located on the intake manifold. Fuel does not enter the intake manifold through the throttle body. Fuel is sprayed into the manifold by the fuel injectors. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body - Removal Throttle Body: Service and Repair Throttle Body - Removal 5.7L 1. Disconnect the negative battery cable. 2. Remove air duct and air resonator box at throttle body 3. Disconnect electrical connector at throttle body. 4. Remove four throttle body mounting bolts. 5. Remove throttle body from intake manifold. 6. Check condition of throttle body O-ring (1), replace if damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body - Removal > Page 4341 Throttle Body: Service and Repair Throttle Body - Installation 5.7L 1. Check condition of throttle body O-ring (1) and replace as necessary. 2. Clean mating surfaces of throttle body and intake manifold. 3. Position throttle body in place 4. Install throttle body mounting bolts. CAUTION: The throttle body mounting bolts MUST be tightened to specifications. Over tightening can cause damage to the throttle body or the intake manifold. 5. Tighten mounting bolts to 5.6 Nm (50 in. lbs.) in the sequence shown. 6. Install electrical connector (2). 7. Install air plenum to flange (3). 8. Connect negative battery cable. 9. Using the diagnostic scan tool, perform the ETC Relearn function. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System > Variable Induction Control Solenoid > Component Information > Diagrams Variable Induction Control Solenoid: Diagrams Connector (5.7L) - (ENGINE) 4 WAY SOLENOID-SHORT RUNNER VALVE (5.7L) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications ENGINE FIRING ORDER - 5.7L The firing order for the 5.7L V-8 is 1-8-4-3-6-5-7-2. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > System Information > Specifications Ignition Timing: Specifications IGNITION TIMING Ignition timing is not adjustable on any of the available engines. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor > Page 4357 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4358 Camshaft Position Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-CAMSHAFT POSITION - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description 5.7L The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 4361 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation 5.7L The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.7L The Camshaft Position Sensor (CMP) (3) is located on right side of timing gear/chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from timing gear/chain cover. 4. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 4364 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in timing gear/chain cover. 2. Install sensor (2) into timing gear/chain cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing gear/chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 Nm (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Condenser, Ignition > Component Information > Locations > Page 4368 Condenser: Diagrams Connector - (ENGINE) 2 WAY CAPACITOR-IGNITION - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4372 Crankshaft Position Sensor: Diagrams Connector (5.7L) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (5.7L) - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description 5.7L The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 4375 Crankshaft Position Sensor: Description and Operation Operation 5.7L Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On the 5.7L V-8 engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 5.7L 1. Raise vehicle. 2. Disconnect CKP electrical connector (2) at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 4378 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking and twisting action. CAUTION: Before tightening the CKP sensor mounting bolt, be sure the sensor is completely flush to the cylinder block. If the CKP sensor is not flush, damage to the sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Ignition Coil: Specifications IGNITION COIL RESISTANCE - 5.7L Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (5.7L) > Page 4384 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (5.7L) > Page 4385 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (5.7L) > Page 4386 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (5.7L) > Page 4387 Ignition Coil: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (5.7L) > Page 4388 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (5.7L) > Page 4389 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (5.7L) > Page 4390 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (5.7L) > Page 4391 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (5.7L) > Page 4392 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (5.7L) > Page 4393 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Locations > Ignition Coil 1 (5.7L) > Page 4394 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 3 Way Ignition Coil: Diagrams Ignition Coil 1 3 Way Connector - (ENGINE) 3 WAY COIL-IGNITION 1 - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 3 Way > Page 4397 Ignition Coil: Diagrams Ignition Coil 3 3 Way Connector - (ENGINE) 3 WAY COIL-IGNITION 3 - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 3 Way > Page 4398 Ignition Coil: Diagrams Ignition Coil 5 3 Way Connector - (ENGINE) 3 WAY COIL-IGNITION 5 - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 3 Way > Page 4399 Ignition Coil: Diagrams Ignition Coil 2 (Engine) 3 Way Connector - (ENGINE) 3 WAY COIL-IGNITION 2 - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 3 Way > Page 4400 Ignition Coil: Diagrams Ignition Coil 1 3 Way Connector - (ENGINE) 3 WAY COIL-IGNITION 1 - (ENGINE) 3 WAY Ignition Coil 3 3 Way Connector - (ENGINE) 3 WAY COIL-IGNITION 3 - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 3 Way > Page 4401 Ignition Coil 5 3 Way Connector - (ENGINE) 3 WAY COIL-IGNITION 5 - (ENGINE) 3 WAY Ignition Coil 2 (Engine) 3 Way Connector - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 3 Way > Page 4402 COIL-IGNITION 2 - (ENGINE) 3 WAY Ignition Coil 4 (Engine) 3 Way Connector - (ENGINE) 3 WAY COIL-IGNITION 4 - (ENGINE) 3 WAY Ignition Coil 6 (Engine) 3 Way Connector - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 3 Way > Page 4403 COIL-IGNITION 6 - (ENGINE) 3 WAY Ignition Coil 7 (Engine) 3 Way Connector - (ENGINE) 3 WAY COIL-IGNITION 7 - (ENGINE) 3 WAY Ignition Coil 8 (Engine) 3 Way Connector - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Diagrams > Ignition Coil 1 3 Way > Page 4404 COIL-IGNITION 8 - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil - Removal Ignition Coil: Service and Repair Ignition Coil - Removal 5.7L 1. Disconnect the electrical connector (1) from coil (3). 2. Clean area at base of coil with compressed air before removal. 3. Remove two mounting bolts (2) (note that mounting bolts are retained to coil). 4. Carefully pull up coil (1) from valve cover. 5. Remove coil (1) from vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Service and Repair > Ignition Coil - Removal > Page 4407 Ignition Coil: Service and Repair Ignition Coil - Installation 5.7L 1. Using compressed air, blow out any dirt or contaminants from around top of spark plug. NOTE: Use dielectric grease on each of the spark plug boots before installing the coil. 2. Position ignition coil (1) into valve cover and push onto spark plugs. 3. Install 2 coil mounting bolts (2). Tighten to 7 Nm (62 in.lbs.). 4. Connect electrical connector (1) to coil by snapping into position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) Knock Sensor: Locations Knock Sensor 1 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 4412 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 4413 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 4414 Knock Sensor: Locations Knock Sensor 2 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 4415 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way Knock Sensor: Diagrams Knock Sensor 2 (3.7L/5.7L) 2 Way Connector (3.7L/5.7L) - (ENGINE) 2 WAY SENSOR-KNOCK 2 (3.7L/5.7L) - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way > Page 4418 Knock Sensor: Diagrams Knock Sensor 1 (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-KNOCK 1 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor - Description Knock Sensor: Description and Operation Knock Sensor - Description DESCRIPTION 3.7L - Two knock sensors (1) are bolted to the cylinder block under the intake manifold. 4.7L - One knock sensor (1) is bolted to the cylinder block under the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor - Description > Page 4421 5.7L - Two knock sensors (1) are bolted to each side of the cylinder block (outside) under each exhaust manifold (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor - Description > Page 4422 Knock Sensor: Description and Operation Knock Sensor - Operation OPERATION When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric crystal which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal 5.7L Two knock sensors (1) are used. Each sensor is bolted to the outside of the cylinder block below the exhaust manifold (3). 1. Raise the vehicle. 2. Disconnect the knock sensor electrical connector (5). 3. Remove the knock sensor mounting bolt (2). NOTE: Note the foam strip on bolt threads. This foam strip is used only to retain the bolts to the sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove the knock sensor (1) from the engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 4425 Knock Sensor: Service and Repair Knock Sensor - Installation 5.7L 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). NOTE: Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt (2). Tighten to 15 +/- 2 ft. lbs. (20 Nm) (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Camshaft Position Sensor > Page 4431 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4432 Camshaft Position Sensor: Diagrams Connector - (ENGINE) 3 WAY SENSOR-CAMSHAFT POSITION - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Description 5.7L The Camshaft Position Sensor (CMP) (2) is located below the generator on the timing chain / case cover (1) on the right/front side of engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Description and Operation > Camshaft Position Sensor - Description > Page 4435 Camshaft Position Sensor: Description and Operation Camshaft Position Sensor - Operation 5.7L The CMP sensor is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. The sensor generates electrical pulses. These pulses (signals) are sent to the Powertrain Control Module (PCM). The PCM will then determine crankshaft position from both the camshaft position sensor and crankshaft position sensor. The tonewheel is located at the front of the camshaft (2). As the tonewheel rotates, notches (3) pass through the sync signal generator. When the cam gear is rotating, the sensor will detect the notches. Input voltage from the sensor to the PCM will then switch from a low (approximately 0.3 volts) to a high (approximately 5 volts). When the sensor detects a notch has passed, the input voltage switches back low to approximately 0.3 volts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Removal 5.7L The Camshaft Position Sensor (CMP) (3) is located on right side of timing gear/chain cover below generator (1). 1. Disconnect electrical connector (3) at CMP sensor. 2. Remove sensor mounting bolt (3). 3. Carefully twist sensor (2) from timing gear/chain cover. 4. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Service and Repair > Camshaft Position Sensor - Removal > Page 4438 Camshaft Position Sensor: Service and Repair Camshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in timing gear/chain cover. 2. Install sensor (2) into timing gear/chain cover with a slight rocking action. Do not twist sensor into position as damage to O-ring may result. CAUTION: Before tightening sensor mounting bolt, be sure sensor is completely flush to timing gear/chain cover. If sensor is not flush, damage to sensor mounting tang may result. 3. Install mounting bolt (3) and tighten to 12 Nm (106 in.lbs.). 4. Connect electrical connector to sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4442 Crankshaft Position Sensor: Diagrams Connector (5.7L) - (ENGINE) 3 WAY SENSOR-CRANKSHAFT POSITION (5.7L) - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description Crankshaft Position Sensor: Description and Operation Description 5.7L The Crankshaft Position (CKP) sensor is mounted into the right rear side of the cylinder block. It is positioned and bolted into a machined hole. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Description > Page 4445 Crankshaft Position Sensor: Description and Operation Operation 5.7L Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it. On the 5.7L V-8 engine, a tonewheel is bolted to the engine crankshaft. This tonewheel has sets of notches (3) at its outer edge. The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Removal 5.7L 1. Raise vehicle. 2. Disconnect CKP electrical connector (2) at sensor. 3. Remove CKP mounting bolt (3). 4. Carefully twist sensor from cylinder block. 5. Remove sensor from vehicle. 6. Check condition of sensor O-ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > Crankshaft Position Sensor - Removal > Page 4448 Crankshaft Position Sensor: Service and Repair Crankshaft Position Sensor - Installation 5.7L 1. Clean out machined hole in engine block. 2. Apply a small amount of engine oil to sensor O-ring. 3. Install sensor into engine block with a slight rocking and twisting action. CAUTION: Before tightening the CKP sensor mounting bolt, be sure the sensor is completely flush to the cylinder block. If the CKP sensor is not flush, damage to the sensor mounting tang may result. 4. Install mounting bolt and tighten to 28 Nm (21 ft. lbs.) torque. 5. Connect electrical connector to sensor. 6. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Removal Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Removal REMOVAL 1. Disconnect negative cable from battery. 2. Remove the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 3. Remove the tilt lever handle. 4. Remove the lower shroud (2) from steering column. 5. Place shifter in PARK position. The ignition key (2) must be in the key cylinder (1) for cylinder removal. 6. A retaining pin is located at side of key cylinder assembly. a. Rotate key (2) to RUN position. b. Press in on retaining pin with a small punch (3) , while pulling key cylinder (1) from ignition switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Removal > Page 4454 7. Remove the key (2) and key cylinder (1) from the column (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder Removal > Page 4455 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Installation INSTALLATION The ignition key (2) must be in the key cylinder (1) for cylinder installation. 1. Install the key cylinder (1) into the housing (3) using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder (1) in until it clicks. 3. Replace the lower shroud. 4. Install the tilt lever handle. 5. Install the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 6. Reconnect the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) Knock Sensor: Locations Knock Sensor 1 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 4460 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 4461 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 4462 Knock Sensor: Locations Knock Sensor 2 (5.7L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Knock Sensor 1 (5.7L) > Page 4463 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way Knock Sensor: Diagrams Knock Sensor 2 (3.7L/5.7L) 2 Way Connector (3.7L/5.7L) - (ENGINE) 2 WAY SENSOR-KNOCK 2 (3.7L/5.7L) - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Diagrams > Knock Sensor 2 (3.7L/5.7L) 2 Way > Page 4466 Knock Sensor: Diagrams Knock Sensor 1 (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-KNOCK 1 - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor - Description Knock Sensor: Description and Operation Knock Sensor - Description DESCRIPTION 3.7L - Two knock sensors (1) are bolted to the cylinder block under the intake manifold. 4.7L - One knock sensor (1) is bolted to the cylinder block under the intake manifold. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor - Description > Page 4469 5.7L - Two knock sensors (1) are bolted to each side of the cylinder block (outside) under each exhaust manifold (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation > Knock Sensor - Description > Page 4470 Knock Sensor: Description and Operation Knock Sensor - Operation OPERATION When the knock sensor detects a knock in one of the cylinders on the corresponding bank, it sends an input signal to the Powertrain Control Module (PCM). In response, the PCM retards ignition timing for all cylinders by a scheduled amount. Knock sensors contain a piezoelectric crystal which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates. As the intensity of the crystal's vibration increases, the knock sensor output voltage also increases. The voltage signal produced by the knock sensor increases with the amplitude of vibration. The PCM receives the knock sensor voltage signal as an input. If the signal rises above a predetermined level, the PCM will store that value in memory and retard ignition timing to reduce engine knock. If the knock sensor voltage exceeds a preset value, the PCM retards ignition timing for all cylinders. It is not a selective cylinder retard. The PCM ignores knock sensor input during engine idle conditions. Once the engine speed exceeds a specified value, knock retard is allowed. Knock retard uses its own short term and long term memory program. Long term memory stores previous detonation information in its battery-backed RAM. The maximum authority that long term memory has over timing retard can be calibrated. Short term memory is allowed to retard timing up to a preset amount under all operating conditions (as long as rpm is above the minimum rpm) except at Wide Open Throttle (WOT). The PCM, using short term memory, can respond quickly to retard timing when engine knock is detected. Short term memory is lost any time the ignition key is turned off. NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal Knock Sensor: Service and Repair Knock Sensor - Removal 5.7L Two knock sensors (1) are used. Each sensor is bolted to the outside of the cylinder block below the exhaust manifold (3). 1. Raise the vehicle. 2. Disconnect the knock sensor electrical connector (5). 3. Remove the knock sensor mounting bolt (2). NOTE: Note the foam strip on bolt threads. This foam strip is used only to retain the bolts to the sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 4. Remove the knock sensor (1) from the engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor - Removal > Page 4473 Knock Sensor: Service and Repair Knock Sensor - Installation 5.7L 1. Thoroughly clean knock sensor mounting hole. 2. Install sensor (1) into cylinder block (3). NOTE: Over or under tightening the sensor mounting bolts will affect knock sensor performance, possibly causing improper spark control. Always use the specified torque when installing the knock sensors. The torque for the knock sensor bolt is relatively light for an 8 mm bolt (2). NOTE: Note foam strip on bolt threads. This foam is used only to retain the bolts to sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts. 3. Install and tighten mounting bolt (2). Tighten to 15 +/- 2 ft. lbs. (20 Nm) (176 in.lbs.). 4. Install electrical connector to sensor (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Specifications Spark Plug: Specifications Spark Plug Specifications SPARK PLUGS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Spark Plug Specifications > Page 4478 Spark Plug: Specifications Torque SPARK PLUG TORQUES Spark Plugs - 3.7L................................................................................................................................ .......................................................27 Nm (20 ft. lbs.) Spark Plugs - All 4.7L (Upper or Lower row) (New plugs/gaskets).......................................................................................................27±3 Nm (20 ft. lbs.) Spark Plugs - All 4.7L (Upper or Lower row) (Used plugs/gaskets).......................................................................................................22±3 Nm (16 ft. lbs.) **Spark Plugs - 5.7L............................................................................................................................. ........................................ 18(±3) Nm (13(±2) ft. lbs.) ** Torque critical tapered design. Do not exceed 15 ft.lbs. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal Spark Plug: Service and Repair Spark Plug - Removal 5.7L 1. Remove all the necessary air filter tubing and air intake components at the top of the engine and at the throttle body See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal 2. Prior to removing the ignition coil, spray compressed air around the base of the ignition coil at the cylinder head. 3. Remove the ignition coil (1) See: Ignition Coil/Service and Repair/Ignition Coil - Removal 4. Prior to removing the spark plug, spray compressed air into the cylinder head opening. 5. Remove the spark plug from the cylinder head using a quality thin wall socket with a rubber or foam insert. 6. Inspect the spark plug condition. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 4481 Spark Plug: Service and Repair Spark Plug - Installation 5.7L CAUTION: Never use a motorized wire wheel brush to clean spark plugs. Metallic deposits will remain on spark plug insulator and will cause plug misfire. CAUTION: Do not attempt to clean any of the spark plugs. Replace only. 1. Check and adjust the spark plug gap with a gap gauging tool (1) See: Specifications/Spark Plug Specifications. CAUTION: Special care should be taken when installing spark plugs into the cylinder head spark plug wells. Be sure the plugs do not drop into the plug wells as electrodes can be damaged. 2. Start the spark plug into the cylinder head by hand to avoid cross threading. NOTE: Always tighten spark plugs to the specified torque. Certain engines use torque sensitive spark plugs. Over tightening can cause distortion resulting in a change in the spark plug gap, or a cracked porcelain insulator. NOTE: Spark plugs have a torque critical tapered design. Do not exceed 20 Nm (15 ft. lbs.). 3. Tighten the spark plugs to 18 Nm (13 ft. lbs.). 4. To aid in coil installation, apply silicone based grease such as Mopar(R) Dielectric Grease into spark plug end of ignition coil rubber boots. Also apply this grease to the tops of spark plugs. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Service and Repair > Spark Plug - Removal > Page 4482 5. Install the ignition coil(s) (1) See: Ignition Coil/Service and Repair/Ignition Coil - Installation 6. Install all necessary air filter tubing and air intake components to top of engine and to throttle body See: Fuel Delivery and Air Induction/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4492 Shift Interlock Solenoid: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK - (INSTRUMENT PANEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Transfer Case Encoder Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Transfer Case Encoder > Page 4501 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Transfer Case Encoder > Page 4502 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Shift Motor/Mode Sensor Assembly (Engine) 8 Way Transfer Case Actuator: Diagrams Shift Motor/Mode Sensor Assembly (Engine) 8 Way Connector - (ENGINE) 8 WAY ASSEMBLY-SHIFT MOTOR/MODE SENSOR - (ENGINE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Shift Motor/Mode Sensor Assembly (Engine) 8 Way > Page 4505 Transfer Case Actuator: Diagrams Transfer Case Encoder (HEV) (Engine) 3 Way Connector (HEV) - (ENGINE) 3 WAY ENCODER-TRANSFER CASE (HEV) - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Shift Motor/Mode Sensor Assembly (Engine) 8 Way > Page 4506 Transfer Case Actuator: Diagrams Transfer Case Motor (HEV) Engine 4 Way Connector (HEV) - ENGINE 4 WAY MOTOR-TRANSFER CASE (HEV) - ENGINE 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > Shift Motor - Description Transfer Case Actuator: Description and Operation Shift Motor - Description DESCRIPTION The overall function of the shift motor (1) is an electromechanical device consisting of a DC permanent magnet motor and a position holding brake. The shift motors function is to move and lock a gear that moves the range fork and clutch lever found in the transfer case. This allows the transfer case to be shifted electrically to multiple operating positions (4WD AUTO, 4WD LOW and 2WD). The operating current of the shift motor under stall conditions is 30 amps maximum, at 22° C (72° F) with 13.5 volts, at the motor leads. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > Shift Motor - Description > Page 4509 Transfer Case Actuator: Description and Operation Shift Motor - Operation OPERATION Shifting in the transfer case occurs when a Pulse Width Modulated (PWM) voltage is supplied to the shift motor (1) by the Final Drive Control Module (FDCM). A linear analog position sensor (encoder) (3) located on the rear transfer case housing and provides the FDCM with the motor's angular, rotational position. With this information, the FDCM continuously knows the position of the motor, and therefore allows it to accurately control the operation of the motor, including voltage polarity which is used to control motor direction. The electronically controlled wet clutch pack uses an electric motor to actuate an internal gear train, clutch cam, and low range barrel cam. The clutch cam actuates the clutch levers that apply normal force to the multi-disc wet clutch pack. The clutch discs are alternately splined to the front and rear outputs. When normal force is applied to this clutch pack, torque is transferred to equalize speed differences between the front and rear axles. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Shift Motor - Removal Transfer Case Actuator: Service and Repair Shift Motor - Removal REMOVAL NOTE: New shift motor assemblies are shipped in the NEUTRAL position. If a new shift motor assembly must be installed, it will be necessary to shift the transfer case to the NEUTRAL position prior to motor installation. 1. Disconnect the electrical connector from the shift motor. 2. Remove the bolts holding the shift motor to the transfer case. 3. Remove the shift motor (1) from the transfer case. 4. Remove the O-ring seal (2) from the shift motor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Shift Motor - Removal > Page 4512 Transfer Case Actuator: Service and Repair Shift Motor - Installation INSTALLATION NOTE: Before installing the shift motor onto the transfer case, make certain that the shift motor shaft aligns with the transfer case worm shaft accordingly. 1. Install a NEW shift motor o-ring seal (2) onto the shift motor (1). 2. Install the shift motor (1) onto the transfer case. 3. Install the shift motor bolts. Tighten the shift motor bolts to 13 Nm (9 ft. lbs.). 4. Install the electrical wiring harness connector onto the shift motor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Tow/Haul Indicator - Description Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator - Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. The tow/haul indicator is located below the minor gauge set on the left side of the cluster. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Tow/Haul Indicator - Description > Page 4519 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator - Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-on message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - self Test - Each time the cluster is put through the self test, the tow/haul indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transmission control system, the PCM, the CCN, the CAN data bus or the electronic communication related to tow/haul indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description Four Wheel Drive Indicator Lamp: Description and Operation 4WD Indicator - Description 4WD INDICATOR A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD indicator is located below the minor gauge set on the left side of the cluster. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 4525 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Low Indicator - Description 4WD LOW INDICATOR A 4WD low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD low indicator is located below the minor gauge set on the left side of the cluster. The 4WD low indicator consists of a stencil-like cutout of the text 4LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD low indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 4526 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Indicator - Operation 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-on message from the FCM, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the 4WD indicator will be turned ON, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD mode is engaged. The FCM then sends the proper lamp-on or lamp-off message to the instrument cluster also known as the Cab Compartment Node (CCN). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transfer case shift motor/mode sensor, the FCM, the CCN, the CAN data bus or the electronic communication related to 4WD indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 4527 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Low Indicator - Operation 4WD LOW INDICATOR The 4WD low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The 4WD low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the 4WD low indicator for the following reasons: - 4WD Low Indicator Lamp-On Message- Each time the cluster receives an electronic 4WD low indicator lamp-on message from the FCM, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the 4WD low indicator turns on, then off again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The FCM then sends the proper lamp-on or lamp-off message to the Instrument Cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the 4WD low indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transfer case shift motor/mode sensor, the FCM, the CCN, the CAN data bus or the electronic communication related to 4WD low indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Service 4WD Indicator - Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Service 4WD Indicator Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located below the minor gauge set on the left side of the cluster. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Service 4WD Indicator - Description > Page 4532 Malfunction Indicator Lamp - Transfer Case: Description and Operation Service 4WD Indicator Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Front Control Module (FCM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the FCM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-on message from the FCM, the service 4WD indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-off messages from the FCM for 10 seconds, the service 4WD indicator is illuminated by the cluster to indicate a loss of FCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the FCM. - Self Test - Each time the cluster is put through the self test, the service 4WD indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The FCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the FCM, the CCN, the CAN data bus or the electronic communication related to service 4WD indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description Control Module: Description and Operation Transmission Control Module - Description DESCRIPTION RFE - RLE TRANSMISSIONS The Transmission Control Module (TCM) is a sub-module within the Powertrain Control Module (PCM). The PCM is located on the right inner fender. EVT AHS-T TRANSMISSION TEHCM MOUNTING BOLTS On vehicles equipped with the AHS-T HEV transmission the TCM is imbedded into the Transmission Electronic Hydraulic Control Module (TECHM) that is mounted to the valve body and is not serviceable, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 4539 Control Module: Description and Operation Transmission Control Module - Operation OPERATION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. See: Computers and Control Systems/Testing and Inspection/Programming and Relearning/TCM Quick Learn BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 4540 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: 42RLE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 4541 545RFE EVT AHS-T SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 4542 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures Control Module: Procedures STANDARD PROCEDURE - RESOLVER LEARN RESOLVER OFFSET LEARN TRIGGER EVT AHS-T TRANSMISSION The Resolver Offset Learn Trigger Procedure requires the use of a scan tool. This program allows the electronic variable transmission (EVT) AHS-T to re-calibrate itself. This will provide the proper transmission operation. The resolver offset learn procedure should be performed if any of the following procedures are performed: - Transmission Assembly Replacement - Transmission Electronic Hydraulic Control Module (TEHCM) Replacement - Flashing the TCM - Electric Motors Replacement - Valve Body Replacement or Recondition To perform the Resolver Offset Learn Trigger Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The shift lever position must stay in PARK until prompted to shift. - The calculated oil temperature must be above 15° C (60° F) and below 93° C (200° F) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4545 Control Module: Removal and Replacement Transmission Control Module - Removal REMOVAL WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. NOTE: If the TECHM is being flashed, removed or replaced, it is necessary to perform the Resolver Offset Learn Trigger procedure using the scan tool. 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove the drain plug, if equipped. 4. Remove the auxiliary oil pump mounting bolts (1). 5. Remove the auxiliary oil pump (2). 6. Remove the transmission oil pan (1), the primary oil filter (2) and the auxiliary oil filter (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4546 7. Lift up the passage sleeve locking tab (1). Remove the passage sleeve by gripping firmly on two ends and pulling the sleeve away. 8. Disconnect the TEHCM 2-way electrical jumper connector (1) from the internal transmission harness. 9. Disconnect the TEHCM electrical connector (1) from the valve body (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4547 10. Remove the TEHCM side mounting bolts (1) and main mounting bolts (2) from the valve body. 11. Disconnect the TEHCM jumper harness. 12. If necessary remove the TECHM filter screen (1). Transmission Control Module - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4548 INSTALLATION WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. NOTE: If the TECHM is being flashed, removed or replaced, it is necessary to perform the Resolver Offset Learn Trigger procedure using the scan tool. 1. Install the filter screen onto the TEHCM. TEHCM JUMPER CONNECTOR 2. Connect the TEHCM jumper harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4549 TEHCM MOUNTING BOLTS 3. Install the TECHM heat sink bolts (1). Tighten the bolts to 7 Nm (62 in.lbs.). 4. Install the TECHM mounting bolts (2). Tighten the bolts to 11 Nm (97 in.lbs.). 5. Connect the 2-way TEHCM electrical connector (1). 6. Connect the TEHCM electrical connector (1) to the valve body. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4550 NOTE: Orientate the alignment tab inside the passage sleeve with the slot in the electrical connector of the control solenoid valve assembly. Push the sleeve straight into the case bore and connector. Do NOT rotate the sleeve at any time. Ensure the sleeve is fully seated into the case. When the sleeve is properly installed, the distance from the case surface to the end of the sleeve should be 14-16 mm. 7. Lubricate the seals on the passage sleeve with DEXRON(R) VI. Install the passage sleeve (2). Push down on the passage locking tab (1) to secure. NOTE: Using a suitable solvent, clean the oil pan and magnet. 8. Install the auxiliary oil filter assembly (3). 9. Install the primary oil filter assembly (2). 10. Install the oil pan gasket and the oil pan (1) onto the transmission case. Install the oil pan bolts. Tighten the oil pan bolts to 27 Nm (19 ft.lbs.). 11. Install the auxiliary oil pump (2) with a NEW gasket. 12. Install the auxiliary oil pump bolts (1). Tighten the bolts to 11 Nm (97 in.lbs.). 13. Check and fill the transmission as necessary with DEXRON(R) VI transmission fluid. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4554 Transmission Control System Relay: Diagrams Connector (IN PDC) RELAY-TRANSMISSION CONTROL (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way Control Module: Diagrams Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way Connector C1 (HEV) - (HEADLAMP AND DASH) 16 WAY MODULE-FINAL DRIVE CONTROL (HEV) - (HEADLAMP AND DASH) 16 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way > Page 4560 Control Module: Diagrams Final Drive Control Module C2 (HEV) (Headlamp And Dash) 4 Way Connector C2 (HEV) - (HEADLAMP AND DASH) 4 WAY MODULE-FINAL DRIVE CONTROL (HEV) - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description Control Module: Description and Operation Final Drive Control Module - Description DESCRIPTION FDCM (Final Drive Control Module) is an electronic module that controls the shifting of the AWD new "Active on Demand" MP3010 single speed transfer case. This plastic cased module is packaged in the (Pedal Assembly) MAG bracket for the HB/HG HEV vehicle. Communication is via the CAN serial bus. The FDCM is installed inside the passenger compartment behind the driver side knee bolster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 4563 Control Module: Description and Operation Final Drive Control Module - Operation OPERATION POWER UP/DOWN The Final Drive Control Module (FDCM) will power up with an OFF/ON transition of the hard wired ignition switch input, or with the presence of active CAN C communications. The FDCM will power down when the vehicle ignition switch transitions from ON to OFF, or there are no CAN C messages, or there are no system requirements that dictate the controller to remain active START-UP DIAGNOSTICS When the FDCM is activated, the internal circuitry will undergo a diagnostic procedure. The controller will examine all inputs and outputs for short circuits to ground, short circuits to battery and open circuits and will also verify proper CPU and memory operation. If a fault is detected, a message will be sent out over the CAN C bus to the Cluster based Electronic Vehicle Information Center (EVIC) indicating that service is recommended. After passing all diagnostic tests, the controller will receive and process inputs and produce the appropriate outputs. Proper monitoring of the controller inputs and outputs performance will continue. INPUTS/OUTPUTS The following are inputs to the FDCM: - Lateral Accelerometer - Transfer Case Mode Sensor Signal - 3 Direct Battery Feeds - Ignition RUN Sense - Sensor Grounds - Module Grounds - CAN C Bus The following are outputs of the FDCM: - 5V Sensor Supply - Transfer Case Bi-directional Motor Control (A AND B) TRANSFER CASE MODE SENSOR SIGNAL The Transfer Case Mode Sensor Signal Input will provide the FDCM feedback about the position of the transfer case. The mode sensor will be a linear analog position sensor with a 1.4K +/- 20% potentiometer and a 1 K +/- 20% resistor that converts the motor shaft position into a multiplexed voltage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 4564 SLIP CONTROL Slip Control increases torque to the front axle when a relative slip is detected between the front and the rear prop shafts. Slip Control adjusts according to the vehicle speed and allows a permissible slip. Utilizes a closed loop strategy for permissible slip and speed of engagement. STABILITY CONTROL Stability control modifies the torque request based upon the vehicle dynamics under the over-steer and under-steer conditions. It monitors the yaw rate and the lateral acceleration to modify the clutch capacity to bring the vehicle back to a more neutral attitude. Compensates for high load conditions by monitoring the vehicle acceleration and changing the torque capacity. REGENERATIVE BRAKING STRATEGY During the event of regenerative braking the software splits the torque indicated by the signal axle in a ratio of 47:53 front and rear respectively. This torque split is to be modified to achieve optimum efficiency levels during a braking event. MODES OF OPERATION Normal Operation This mode is achieved by the ignition being switched in the RUN position, which powers up the 5V regulator and generates the appropriate RESET for the microprocessor. This mode also includes any required power-up system checks. Shut Down Mode This mode is activated when the ignition switch turned to the off position. The FDCM will perform any required Shut Down tasks prior to turning off the 5V regulator. Limp-In Mode This mode is entered when the FDCM has detected an error condition that prevents the system from performing its' required task. The FDCM operation will vary depending from modified operation to total system shut down based on the failure that has occurred. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal Control Module: Service and Repair Final Drive Control Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect the module electrical connectors. 3. Using a trim stick C-4755 or equivalent, gently pry back on the retaining tabs on the mounting plate and remove module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal > Page 4567 Control Module: Service and Repair Final Drive Control Module - Installation INSTALLATION 1. Place the final drive control module in its location on the mounting plate and firmly snap into place. 2. Connect the electrical connectors. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4573 Fluid Pressure Sensor/Switch: Diagrams Connector (4.7L/5.7L) - (ENGINE) 4 WAY SENSOR-LINE PRESSURE (4.7L/5.7L) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4577 Overdrive Switch: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SWITCH-TOW/HAUL OVERDRIVE - (INSTRUMENT PANEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Overdrive Lockout Switch - Description Overdrive Switch: Description and Operation Overdrive Lockout Switch - Description DESCRIPTION The tow/haul on control switch is located in the shift lever arm. The switch is a momentary contact device that signals the Powertrain Control Module (PCM) to toggle current status of the overdrive function. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Overdrive Lockout Switch - Description > Page 4580 Overdrive Switch: Description and Operation Overdrive Lockout Switch - Operation OPERATION Tow/haul is only used in the D position. When used while towing, the electronic control module (ECU) commands hybrid system to create more positive axle torque to the wheels. When used while coasting downhill and the vehicle gains speed, the ECU commands the hybrid system to create more negative axle torque to the wheels, helping the vehicle to maintain the correct speed. The Powertrain Control Module (PCM) stores a target speed when the accelerator and brake are released, if vehicle speed increases due to a hill, then additional negative wheel torque is added to the PCMs wheel torque request. The Hybrid Control Processor (HCP) follows the PCMs command and downshifts as required to meet the negative torque request. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Overdrive Lockout Switch - Removal Overdrive Switch: Service and Repair Overdrive Lockout Switch - Removal REMOVAL 1. Using a plastic trim tool (3), remove the tow/haul switch retainer (2) from the gearshift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Overdrive Lockout Switch - Removal > Page 4583 Overdrive Switch: Service and Repair Overdrive Lockout Switch - Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul switch (3) into the connector (2). 3. Push the tow/haul switch (3) and wiring into the shift lever (1). 4. Install the tow/haul switch retainer onto the shift lever. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4587 Transmission Position Switch/Sensor: Diagrams Connector (HEV) - (TRANSMISSION SIDE) 12 WAY SENSOR-TRANSMISSION RANGE (HEV) - (TRANSMISSION SIDE) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Description DESCRIPTION The transmission range sensor (2) is located inside the transmission and connects to the mainshaft (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description > Page 4590 Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Disconnect the transmission range sensor electrical connector (1). 3. Remove the bolt (1) securing the transmission range sensor (2) to the mainshaft (3). 4. Remove the mainshaft roll pin (1) from the transmission case (2) and remove the mainshaft. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4593 5. Lower the transmission range sensor (2) and remove the park actuator rod (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4594 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install the park actuator rod (3) into the transmission range sensor (2). 2. Install the mainshaft roll pin (1) to the transmission case (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4595 3. Position the transmission range sensor (2) into place in the transmission case. 4. Install the mainshaft (3) into the transmission case. 5. Install the transmission range sensor mounting bolt. Tighten the bolt to 8 Nm (71 NOTE: Before install the TEHCM / valve body assembly to the transmission case, be certain the existing gasket is in place. 6. Install the valve body. See: Transmission and Drivetrain/Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 4600 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 4601 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way Transmission Speed Sensor: Diagrams Input Speed Sensor (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-INPUT SPEED - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way > Page 4604 Transmission Speed Sensor: Diagrams Output Speed Sensor (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-OUTPUT SPEED - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way > Page 4605 Transmission Speed Sensor: Diagrams Output Speed Sensor (HEV) Engine 2 Way Connector (HEV) - ENGINE 2 WAY SENSOR-OUTPUT SPEED (HEV) - ENGINE 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Oil Temperature Sensor - Description Transmission Temperature Sensor/Switch: Description and Operation Transmission Oil Temperature Sensor - Description DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Electronic Hydraulic Control Module (TEHCM). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Oil Temperature Sensor - Description > Page 4610 Transmission Temperature Sensor/Switch: Description and Operation Transmission Oil Temperature Sensor - Operation OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature. - Engine coolant temperature. - In-gear run time since start-up. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 4615 Four Wheel Drive Selector Switch: Diagrams Connector - (INSTRUMENT PANEL) 10 WAY SWITCH-TRANSFER CASE SELECTOR - (INSTRUMENT PANEL) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 4619 Gear Sensor/Switch: Diagrams Connector - (ENGINE) 8 WAY ASSEMBLY-SHIFT MOTOR/MODE SENSOR - (ENGINE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > Mode Sensor - Description Gear Sensor/Switch: Description and Operation Mode Sensor - Description DESCRIPTION The transfer case encoder (3) provides the Drive Train Control Module (DTCM) feedback about the position of the transfer case. The sensor consists of a linear analog position sensor that converts the motor output shaft position into a DC signal. The sensor may rotate a full 360 degrees. When the DTCM is not in sleep mode, it must supply 5 VDC (+/- 0.5 v) to the sensor and monitor the shift motor position. The sensor position is monitored when the ignition is in the RUN position and for 10 seconds after the ignition is turned to the OFF position. The sensor is mechanically linked to the shaft of the cam allowing the transfer case to shift. The mode sensor draws less than 20 mA of current during operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > Mode Sensor - Description > Page 4622 Gear Sensor/Switch: Description and Operation Mode Sensor - Operation OPERATION During normal vehicle operation, the DTCM monitors the mode sensor outputs at least every 2 milliseconds when the shift motor is stationary or active. The mode sensor position will be considered invalid by the DTCM if the voltage is greater than 4.75 V or if it is less than 0.25 V. NOTE: All the parameter voltages referred to in the following information are calibrated items in the controller software and are subject to change. The DTCM shall consider Transfer Case position based on the MODE SENSOR VOLTAGES table listed below: MODE SENSOR VOLTAGES Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Mode Sensor - Removal Gear Sensor/Switch: Service and Repair Mode Sensor - Removal REMOVAL 1. Remove the wiring harness electrical connector from the encoder. 2. Remove the screws securing the encoder to the rear transfer case housing. 3. Remove the encoder (1) from the transfer case (2). 4. Remove the O-ring seal (1) from the encoder (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Mode Sensor - Removal > Page 4625 Gear Sensor/Switch: Service and Repair Mode Sensor - Installation INSTALLATION 1. Install a NEW O-ring seal (1) onto the encoder (2). NOTE: Before installing the encoder onto the transfer case, be certain to align the encoder shaft to the shift shaft and the dowel on the encoder to the hole in the case accordingly. 2. Install the encoder (1) onto the rear transfer case housing (2). 3. Install the encoder screws. Tighten the screws to 7 Nm (62 in.lbs.). 4. Install the electrical wiring harness connector onto the encoder. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-002-10 > Jan > 10 > Hybrid Systems - MIL ON/Multiple DTC's Set PROM - Programmable Read Only Memory: Customer Interest Hybrid Systems - MIL ON/Multiple DTC's Set NUMBER: 08-002-10 GROUP: Electrical DATE: January 26, 2010 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P2096, P2097, P2098, P2099, P0420, P0430, P0606, P0776, P0752, P061B, P079B/A and POA8D. OVERVIEW: This bulletin involves flashing the Hybrid Control Processor (HCP), PCM module, Trans Control (TEHCM), and Accessory Power Module (APM) with new software. MODELS: 2009 HB Durango 2009 HG Aspen NOTE: This bulletin applies to HEV vehicles only (sales code EZE). SYMPTOM/CONDITION: Customers may experience an intermittent MIL Lamp with a code of P2096, P2097, P2098, and P2099, with no driveability complaints. Calibration update for the PCM will also address detonation knocking, and codes P0420 and P0430 that the customer may experience. For the TEHCM the software will eliminate the latching of P0606 caused by performing other flashes. It will prevent P0776 to set when P0752 is active. It will also improve diagnostics for the clutch 2 hydraulic system. For the HCP, the software change will reduce the possibility for P061B torque security to set before P079B/A Transmission Friction Element 2/1 Slip Detected code stored in the TEHCM, allowing for improved diagnostics. For the APM the software is for code POA8D APM system voltage low. This code may be found during a vehicle scan. It will not turn on the MIL and there will not be any driveability issues. DIAGNOSIS: If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the TEHCM with the latest software First followed by the PCM, HCP and APM modules using the wiTECH tool. Using the wiTECH Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 08-002-10 > Jan > 10 > Hybrid Systems - MIL ON/Multiple DTC's Set > Page 4634 Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP tab on upper portion of the wiTECH window, then "HELP CONTENTS. This will open the Welcome to wiTECH Help screen were help topics can now selected. After all modules are reprogrammed, the following must be performed: 2. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-002-10 > Jan > 10 > Hybrid Systems - MIL ON/Multiple DTC's Set PROM - Programmable Read Only Memory: All Technical Service Bulletins Hybrid Systems - MIL ON/Multiple DTC's Set NUMBER: 08-002-10 GROUP: Electrical DATE: January 26, 2010 THE wiTECH DIAGNOSTIC APPLICATION IS THE PREFERRED METHOD FOR FLASHING ECUs. HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS AVAILABLE BY SELECTING "HELP" THEN "HELP CONTENTS" AT THE TOP OF THE wiTECH DIAGNOSTIC APPLICATION WINDOW. THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 10.02 OR HIGHER TO PERFORM THIS PROCEDURE. StarMOBILE DESKTOP CLIENT or StarSCAN MAY ALSO BE USED TO PERFORM THIS PROCEDURE. SUBJECT: Flash: MIL Illumination For P2096, P2097, P2098, P2099, P0420, P0430, P0606, P0776, P0752, P061B, P079B/A and POA8D. OVERVIEW: This bulletin involves flashing the Hybrid Control Processor (HCP), PCM module, Trans Control (TEHCM), and Accessory Power Module (APM) with new software. MODELS: 2009 HB Durango 2009 HG Aspen NOTE: This bulletin applies to HEV vehicles only (sales code EZE). SYMPTOM/CONDITION: Customers may experience an intermittent MIL Lamp with a code of P2096, P2097, P2098, and P2099, with no driveability complaints. Calibration update for the PCM will also address detonation knocking, and codes P0420 and P0430 that the customer may experience. For the TEHCM the software will eliminate the latching of P0606 caused by performing other flashes. It will prevent P0776 to set when P0752 is active. It will also improve diagnostics for the clutch 2 hydraulic system. For the HCP, the software change will reduce the possibility for P061B torque security to set before P079B/A Transmission Friction Element 2/1 Slip Detected code stored in the TEHCM, allowing for improved diagnostics. For the APM the software is for code POA8D APM system voltage low. This code may be found during a vehicle scan. It will not turn on the MIL and there will not be any driveability issues. DIAGNOSIS: If the vehicle operator describes or experiences the Symptom/Condition, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Reprogram the TEHCM with the latest software First followed by the PCM, HCP and APM modules using the wiTECH tool. Using the wiTECH Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 08-002-10 > Jan > 10 > Hybrid Systems - MIL ON/Multiple DTC's Set > Page 4640 Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP tab on upper portion of the wiTECH window, then "HELP CONTENTS. This will open the Welcome to wiTECH Help screen were help topics can now selected. After all modules are reprogrammed, the following must be performed: 2. Clear any DTC's that may have been set in other modules due to reprogramming. The wiTECH application will automatically present all DTC's after the flash and allow the tech to clear them. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4650 Shift Interlock Solenoid: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK - (INSTRUMENT PANEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Transfer Case Encoder Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Transfer Case Encoder > Page 4659 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Transfer Case Encoder > Page 4660 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Shift Motor/Mode Sensor Assembly (Engine) 8 Way Transfer Case Actuator: Diagrams Shift Motor/Mode Sensor Assembly (Engine) 8 Way Connector - (ENGINE) 8 WAY ASSEMBLY-SHIFT MOTOR/MODE SENSOR - (ENGINE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Shift Motor/Mode Sensor Assembly (Engine) 8 Way > Page 4663 Transfer Case Actuator: Diagrams Transfer Case Encoder (HEV) (Engine) 3 Way Connector (HEV) - (ENGINE) 3 WAY ENCODER-TRANSFER CASE (HEV) - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Shift Motor/Mode Sensor Assembly (Engine) 8 Way > Page 4664 Transfer Case Actuator: Diagrams Transfer Case Motor (HEV) Engine 4 Way Connector (HEV) - ENGINE 4 WAY MOTOR-TRANSFER CASE (HEV) - ENGINE 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > Shift Motor - Description Transfer Case Actuator: Description and Operation Shift Motor - Description DESCRIPTION The overall function of the shift motor (1) is an electromechanical device consisting of a DC permanent magnet motor and a position holding brake. The shift motors function is to move and lock a gear that moves the range fork and clutch lever found in the transfer case. This allows the transfer case to be shifted electrically to multiple operating positions (4WD AUTO, 4WD LOW and 2WD). The operating current of the shift motor under stall conditions is 30 amps maximum, at 22° C (72° F) with 13.5 volts, at the motor leads. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > Shift Motor - Description > Page 4667 Transfer Case Actuator: Description and Operation Shift Motor - Operation OPERATION Shifting in the transfer case occurs when a Pulse Width Modulated (PWM) voltage is supplied to the shift motor (1) by the Final Drive Control Module (FDCM). A linear analog position sensor (encoder) (3) located on the rear transfer case housing and provides the FDCM with the motor's angular, rotational position. With this information, the FDCM continuously knows the position of the motor, and therefore allows it to accurately control the operation of the motor, including voltage polarity which is used to control motor direction. The electronically controlled wet clutch pack uses an electric motor to actuate an internal gear train, clutch cam, and low range barrel cam. The clutch cam actuates the clutch levers that apply normal force to the multi-disc wet clutch pack. The clutch discs are alternately splined to the front and rear outputs. When normal force is applied to this clutch pack, torque is transferred to equalize speed differences between the front and rear axles. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Shift Motor - Removal Transfer Case Actuator: Service and Repair Shift Motor - Removal REMOVAL NOTE: New shift motor assemblies are shipped in the NEUTRAL position. If a new shift motor assembly must be installed, it will be necessary to shift the transfer case to the NEUTRAL position prior to motor installation. 1. Disconnect the electrical connector from the shift motor. 2. Remove the bolts holding the shift motor to the transfer case. 3. Remove the shift motor (1) from the transfer case. 4. Remove the O-ring seal (2) from the shift motor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Shift Motor - Removal > Page 4670 Transfer Case Actuator: Service and Repair Shift Motor - Installation INSTALLATION NOTE: Before installing the shift motor onto the transfer case, make certain that the shift motor shaft aligns with the transfer case worm shaft accordingly. 1. Install a NEW shift motor o-ring seal (2) onto the shift motor (1). 2. Install the shift motor (1) onto the transfer case. 3. Install the shift motor bolts. Tighten the shift motor bolts to 13 Nm (9 ft. lbs.). 4. Install the electrical wiring harness connector onto the shift motor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4679 Shift Interlock Solenoid: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK - (INSTRUMENT PANEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description Control Module: Description and Operation Transmission Control Module - Description DESCRIPTION RFE - RLE TRANSMISSIONS The Transmission Control Module (TCM) is a sub-module within the Powertrain Control Module (PCM). The PCM is located on the right inner fender. EVT AHS-T TRANSMISSION TEHCM MOUNTING BOLTS On vehicles equipped with the AHS-T HEV transmission the TCM is imbedded into the Transmission Electronic Hydraulic Control Module (TECHM) that is mounted to the valve body and is not serviceable, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 4687 Control Module: Description and Operation Transmission Control Module - Operation OPERATION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning/TCM Quick Learn BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 4688 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: 42RLE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 4689 545RFE EVT AHS-T SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 4690 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Procedures Control Module: Procedures STANDARD PROCEDURE - RESOLVER LEARN RESOLVER OFFSET LEARN TRIGGER EVT AHS-T TRANSMISSION The Resolver Offset Learn Trigger Procedure requires the use of a scan tool. This program allows the electronic variable transmission (EVT) AHS-T to re-calibrate itself. This will provide the proper transmission operation. The resolver offset learn procedure should be performed if any of the following procedures are performed: - Transmission Assembly Replacement - Transmission Electronic Hydraulic Control Module (TEHCM) Replacement - Flashing the TCM - Electric Motors Replacement - Valve Body Replacement or Recondition To perform the Resolver Offset Learn Trigger Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The shift lever position must stay in PARK until prompted to shift. - The calculated oil temperature must be above 15° C (60° F) and below 93° C (200° F) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4693 Control Module: Removal and Replacement Transmission Control Module - Removal REMOVAL WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. NOTE: If the TECHM is being flashed, removed or replaced, it is necessary to perform the Resolver Offset Learn Trigger procedure using the scan tool. 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove the drain plug, if equipped. 4. Remove the auxiliary oil pump mounting bolts (1). 5. Remove the auxiliary oil pump (2). 6. Remove the transmission oil pan (1), the primary oil filter (2) and the auxiliary oil filter (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4694 7. Lift up the passage sleeve locking tab (1). Remove the passage sleeve by gripping firmly on two ends and pulling the sleeve away. 8. Disconnect the TEHCM 2-way electrical jumper connector (1) from the internal transmission harness. 9. Disconnect the TEHCM electrical connector (1) from the valve body (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4695 10. Remove the TEHCM side mounting bolts (1) and main mounting bolts (2) from the valve body. 11. Disconnect the TEHCM jumper harness. 12. If necessary remove the TECHM filter screen (1). Transmission Control Module - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4696 INSTALLATION WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. NOTE: If the TECHM is being flashed, removed or replaced, it is necessary to perform the Resolver Offset Learn Trigger procedure using the scan tool. 1. Install the filter screen onto the TEHCM. TEHCM JUMPER CONNECTOR 2. Connect the TEHCM jumper harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4697 TEHCM MOUNTING BOLTS 3. Install the TECHM heat sink bolts (1). Tighten the bolts to 7 Nm (62 in.lbs.). 4. Install the TECHM mounting bolts (2). Tighten the bolts to 11 Nm (97 in.lbs.). 5. Connect the 2-way TEHCM electrical connector (1). 6. Connect the TEHCM electrical connector (1) to the valve body. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4698 NOTE: Orientate the alignment tab inside the passage sleeve with the slot in the electrical connector of the control solenoid valve assembly. Push the sleeve straight into the case bore and connector. Do NOT rotate the sleeve at any time. Ensure the sleeve is fully seated into the case. When the sleeve is properly installed, the distance from the case surface to the end of the sleeve should be 14-16 mm. 7. Lubricate the seals on the passage sleeve with DEXRON(R) VI. Install the passage sleeve (2). Push down on the passage locking tab (1) to secure. NOTE: Using a suitable solvent, clean the oil pan and magnet. 8. Install the auxiliary oil filter assembly (3). 9. Install the primary oil filter assembly (2). 10. Install the oil pan gasket and the oil pan (1) onto the transmission case. Install the oil pan bolts. Tighten the oil pan bolts to 27 Nm (19 ft.lbs.). 11. Install the auxiliary oil pump (2) with a NEW gasket. 12. Install the auxiliary oil pump bolts (1). Tighten the bolts to 11 Nm (97 in.lbs.). 13. Check and fill the transmission as necessary with DEXRON(R) VI transmission fluid. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Differential Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4704 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - A/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4709 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications EVT/ASH-T Transmission Service Fill ........................................................................................................................................... ........................................................ 23.2 pts (11.0L) Overhaul Fill ........................................................................................................................................ ......................................................... 26.4 pts (12.5L) Dry fill capacity, depending on the type and size of the internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler. These figures may vary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4712 Fluid - A/T: Fluid Type Specifications EVT/ASH-T Transmission ................................................................................................................... ................................................................. Dexron VI Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4713 Fluid - A/T: Description and Operation AUTOMATIC TRANSMISSION FLUID NOTE: Refer to Service Procedures for fluid level checking procedures. Dexron VI Automatic Transmission Fluid is the only recommended fluid for the Hybrid transmission. Mopar(R) ATF +4, Automatic Transmission Fluid is the recommended fluid for most Chrysler automatic transmissions. Dexron II fluid IS NOT recommended. Clutch chatter can result from the use of improper fluid. Mopar(R) ATF +4 as well as Dexron VI Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. FLUID ADDITIVES Chrysler strongly recommends against the addition of any fluids to the transmission, other than those automatic transmission fluids listed above. Exceptions to this policy are the use of special dyes to aid in detecting fluid leaks. Various "special" additives and supplements exist that claim to improve shift feel and/or quality. These additives and others also claim to improve converter clutch operation and inhibit overheating, oxidation, varnish, and sludge. These claims have not been supported to the satisfaction of Chrysler and these additives must not be used. The use of transmission "sealers" should also be avoided, since they may adversely affect the integrity of transmission seals. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level Fluid - A/T: Testing and Inspection Effects of Incorrect Fluid Level EFFECTS OF INCORRECT FLUID LEVEL A low fluid level allows the pump to take in air along with the fluid. Air in the fluid will cause fluid pressures to be low and develop slower than normal. If the transmission is overfilled, the gears churn the fluid into foam. This aerates the fluid and causing the same conditions occurring with a low level. In either case, air bubbles cause fluid overheating, oxidation, and varnish buildup which interferes with valve and clutch operation. Foaming also causes fluid expansion which can result in fluid overflow from the transmission vent or fill tube. Fluid overflow can easily be mistaken for a leak if inspection is not careful. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 4716 Fluid - A/T: Testing and Inspection Causes of Burnt Fluid CAUSES OF BURNT FLUID Burnt, discolored fluid is a result of overheating which has three primary causes. 1. Internal clutch slippage, usually caused by low line pressure, inadequate clutch apply pressure, or clutch seal failure. 2. A result of restricted fluid flow through the main and auxiliary cooler. This condition is usually the result of a faulty or improperly installed drain back valve, a damaged oil cooler, or severe restrictions in the coolers and lines caused by debris or kinked lines. 3. Heavy duty operation with a vehicle not properly equipped for this type of operation. Trailer towing or similar high load operation will overheat the transmission fluid if the vehicle is improperly equipped. Such vehicles should have an auxiliary transmission fluid cooler, a heavy duty cooling system, and the engine/axle ratio combination needed to handle heavy loads. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Testing and Inspection > Effects of Incorrect Fluid Level > Page 4717 Fluid - A/T: Testing and Inspection Fluid Contamination FLUID CONTAMINATION Transmission fluid contamination is generally a result of: - adding incorrect fluid. - failure to clean dipstick and fill tube when checking level. - engine coolant entering the fluid. - internal failure that generates debris. - overheat that generates sludge (fluid breakdown). - failure to replace contaminated damper after repair. The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. Wipe the dipstick cap and fill tube clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission, an overhaul is necessary. Replace the transmission damper whenever a failure generates sludge and debris. Normal flushing procedures will not remove all contaminants. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check Fluid - A/T: Service and Repair Fluid Level Check FLUID LEVEL CHECK The 2 - Mode EVT transmission uses special Dexron VI oil. Do not use Chrysler MS-9602 oil in the 2 - Mode EVT. A service dipstick, (dipstick 9336A) is required to check the oil level in the 2 - Mode EVT transmission. The fill tube is located on the right side of the engine and is accessed through the right front wheel well. To avoid contaminating the transmission fluid, make sure to clean all dirt and debris from the fill tube cap and around the fill tube opening before removing the fill tube cap. The torque damper fills with fluid in both the P (Park) and N (Neutral)positions. Place the selector lever in P (PARK) to make sure that the fluid level check is accurate. The engine should be running at idle speed for at least one minute with the vehicle on level ground. At normal operating temperature the fluid level is correct if it is at the level shown in the table below on the service dipstick. After the fluid has been checked, seat the fill tube cap fully on the fill tube opening to seal out contaminants. CAPPED FILL TUBE WARNING: This vehicle has two modes of operation. Even with the gas engine off, the vehicle is still capable of moving in electric only mode. When the engine is running, there is also the risk of personal injury or property damage from the vehicle unintentionally being placed into a drive gear and moving. Verify the parking brake is operating correctly, and apply the parking brake while checking the transmission fluid level. There is a risk of injury from rotating or hot parts on the engine when it has been run or when it is running. Secure vehicle to prevent it from moving off by itself. Wear properly fastened and close-fitting work clothes. Do not touch hot or rotating parts. 1. Verify that the vehicle is parked on a level surface. Apply the parking brake. 2. Turn the key on and connect the scan tool to the data link connector. 3. Remove the fill tube cap. 4. Start the engine and let it run at idle speed in the selector lever position "P" until the engine reaches normal operating temperature. 5. Apply and hold the service brake. Shift the transmission into DRIVE for approximately two seconds with the vehicle stationary and the engine idling. 6. Shift the transmission into REVERSE for approximately two seconds with the vehicle stationary and the engine idling. 7. Shift the transmission into park. 8. Use the scan tool to view the transmission fluid temperature sensor. 9. Compare the transmission fluid temperature shown on the scan tool with the transmission fluid level chart. 10. Adjust the transmission fluid level shown on the dipstick according to the transmission fluid temperature chart. NOTE: After adding fluid to the transmission, wait a minimum of two minutes for the oil to fully drain from the fill tube into the transmission before rechecking the fluid level. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 4720 Fluid - A/T: Service and Repair Fluid/Filter Service FLUID AND FILTER REPLACEMENT WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. REMOVAL 1. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair. 2. Disconnect the transmission auxiliary oil pump electrical connector. 3. Remove the bolt (1) securing the auxiliary oil pump harness (2) to the transmission bellhousing (3). 4. Remove the transmission auxiliary oil pump bolts (1) and then remove the pump (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 4721 5. Place a suitable container under the transmission pan (1). 6. Remove the drain plug, if equipped. 7. Remove bolts holding front and sides of oil pan to transmission. 8. Loosen bolts holding rear of oil pan to transmission. 9. Slowly separate front of oil pan (1) away from transmission (4), allowing the fluid to drain into the drain pan. 10. Supporting the oil pan, remove remaining bolts securing pan to transmission. 11. While holding the oil pan level, lower it from transmission. 12. Pour any remaining fluid in pan into drain pan. 13. Separate the primary (2) and auxiliary (3) oil filters from valve body and oil pump and pour fluid from the filters into drain pan. 14. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove with a suitable tool, and discard the oil filter seals from the bottom of the oil pump. If the seals are installed correctly and are in good condition, they can be reused. 15. Dispose of used transmission fluid and filter(s) properly. INSPECTION Inspect the bottom of the oil pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the oil pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and oil pan are contaminated with excessive amounts of debris, refer to the diagnosis section. CLEANING 1. Using a suitable solvent, clean the oil pan and magnet. INSTALLATION CAUTION: The primary and auxiliary oil filter seals MUST be fully installed flush against the oil pump body. DO NOT install the seals onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install new primary (2) and auxiliary (2) oil filter seals in the oil pump inlet bore. Seat the seal in the bore with Installer 6960 or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place new primary (2) and auxiliary (3) oil filters in position on valve body and into the oil pump. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 4722 3. Position the oil pan (1) on transmission. 4. Install bolts to secure pan to transmission. Tighten the oil pan bolts to 27 Nm (20 ft. lbs.). 5. Install the auxiliary oil pump (2). Install the bolts (1) and tighten to 11 Nm (8 ft. lbs.). 6. Install the bolt (1) securing the auxiliary oil pump harness (2) to the transmission bellhousing (3). Tighten the bolt to 11 Nm (8 ft. lbs.). 7. Connect the auxiliary oil pump electrical connector. 8. Lower the vehicle and remove. 9. Fill the transmission with DEXRON(R) VI. See: Service and Repair/Procedures/Transmission Fill Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Fluid Level Check > Page 4723 Fluid - A/T: Service and Repair Transmission Fill TRANSMISSION FILL To avoid overfilling the transmission after a fluid change or overhaul, perform the following procedure: 1. Remove the cap on the filler tube and insert a clean funnel in the transmission fill tube. 2. Add following initial quantity of DEXRON(R) VI to the transmission: a. If only fluid and filters are being changed, add 23.2 pints (11.0 liters) of DEXRON(R) VI to transmission. b. If transmission was completely overhauled and the damper was replaced or drained, add 28.5 pints (13.5 liters) of DEXRON(R) VI to the transmission. 3. Check the transmission fluid and adjust as required. . See: Fluid Level Check Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair FLUID AND FILTER REPLACEMENT WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. REMOVAL 1. Raise and support the vehicle. See: Maintenance/Vehicle Lifting/Service and Repair. 2. Disconnect the transmission auxiliary oil pump electrical connector. 3. Remove the bolt (1) securing the auxiliary oil pump harness (2) to the transmission bellhousing (3). 4. Remove the transmission auxiliary oil pump bolts (1) and then remove the pump (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4727 5. Place a suitable container under the transmission pan (1). 6. Remove the drain plug, if equipped. 7. Remove bolts holding front and sides of oil pan to transmission. 8. Loosen bolts holding rear of oil pan to transmission. 9. Slowly separate front of oil pan (1) away from transmission (4), allowing the fluid to drain into the drain pan. 10. Supporting the oil pan, remove remaining bolts securing pan to transmission. 11. While holding the oil pan level, lower it from transmission. 12. Pour any remaining fluid in pan into drain pan. 13. Separate the primary (2) and auxiliary (3) oil filters from valve body and oil pump and pour fluid from the filters into drain pan. 14. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, then remove with a suitable tool, and discard the oil filter seals from the bottom of the oil pump. If the seals are installed correctly and are in good condition, they can be reused. 15. Dispose of used transmission fluid and filter(s) properly. INSPECTION Inspect the bottom of the oil pan and magnet for excessive amounts of metal. A light coating of clutch material on the bottom of the oil pan does not indicate a problem unless accompanied by a slipping condition or shift lag. If fluid and oil pan are contaminated with excessive amounts of debris, refer to the diagnosis section. CLEANING 1. Using a suitable solvent, clean the oil pan and magnet. INSTALLATION CAUTION: The primary and auxiliary oil filter seals MUST be fully installed flush against the oil pump body. DO NOT install the seals onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 1. If necessary, install new primary (2) and auxiliary (2) oil filter seals in the oil pump inlet bore. Seat the seal in the bore with Installer 6960 or another suitable tool (appropriately sized drift or socket, the butt end of a hammer etc.). 2. Place new primary (2) and auxiliary (3) oil filters in position on valve body and into the oil pump. 3. Position the oil pan (1) on transmission. 4. Install bolts to secure pan to transmission. Tighten the oil pan bolts to 27 Nm (20 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4728 5. Install the auxiliary oil pump (2). Install the bolts (1) and tighten to 11 Nm (8 ft. lbs.). 6. Install the bolt (1) securing the auxiliary oil pump harness (2) to the transmission bellhousing (3). Tighten the bolt to 11 Nm (8 ft. lbs.). 7. Connect the auxiliary oil pump electrical connector. 8. Lower the vehicle and remove. 9. Fill the transmission with DEXRON(R) VI. See: Service and Repair/Procedures/Transmission Fill Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair Fluid Line/Hose: Service and Repair QUICK CONNECT FITTING DISASSEMBLY/ASSEMBLY DISCONNECT 1. Remove the dust cap by pulling it straight back off of the quick connect fitting (1). 2. Place the properly sized release tool (4) onto the transmission cooler line with the fingers of the tool facing the quick connect fitting. 3. Slide the release tool down the transmission line and engage the fingers of the tool into the retaining clip. When properly engaged in the clip, the tool will fit flush against the quick connect fitting. 4. Rotate the release tool 60° to expand the retaining clip. 5. While holding the release tool against the quick connect fitting, pull back on the transmission cooler line to remove it. 6. If the quick connect fitting is damaged or leaking at the transmission oil cooler or transmission, remove the fitting. CONNECT Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Page 4732 1. If removed, install the quick connect fitting into the transmission oil cooler or the transmission. Tighten the fitting to 15 Nm (132 in. lbs.). 2. Align the cooler line (3) with the quick connect fitting while pushing straight into the fitting. 3. Push in on the transmission cooler line until a click is heard or felt. 4. Slide the dust cap (4) down the transmission cooler line and snap it over the quick connect fitting until it is fully seated and rotates freely. The dust cap will only snap over the quick connect fitting when the transmission cooler line is properly installed. NOTE: If the dust cap will not snap into place, repeat step 2. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications FLUID PAN Oil Pan Bolts......................................................................................................................................... ......................................................27 Nm (20 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4739 Fluid Pressure Sensor/Switch: Diagrams Connector (4.7L/5.7L) - (ENGINE) 4 WAY SENSOR-LINE PRESSURE (4.7L/5.7L) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Diagrams > Transmission Auxiliary Oil Pump C1 (HEV) (Module Side) 5 Way Fluid Pump: Diagrams Transmission Auxiliary Oil Pump C1 (HEV) (Module Side) 5 Way Connector C1 (HEV) - (MODULE SIDE) 5 WAY MODULE-TRANSMISSION AUXILIARY OIL PUMP (HEV) - (MODULE SIDE) 5 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Diagrams > Transmission Auxiliary Oil Pump C1 (HEV) (Module Side) 5 Way > Page 4745 Fluid Pump: Diagrams Transmission Auxiliary Oil Pump C2 (HEV) (Headlamp And Dash) 5 Way Connector C2 (HEV) - (HEADLAMP AND DASH) 5 WAY MODULE-TRANSMISSION AUXILIARY OIL PUMP (HEV) - (HEADLAMP AND DASH) 5 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Diagrams > Transmission Auxiliary Oil Pump C1 (HEV) (Module Side) 5 Way > Page 4746 Fluid Pump: Diagrams Transmission Auxiliary Oil Pump C1 (HEV) (PUMP Side) 5 Way Connector C1 (HEV) - (PUMP SIDE) 5 WAY PUMP-TRANSMISSION AUXILIARY OIL (HEV) - (PUMP SIDE) 5 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Testing and Inspection > Main Pump Hydraulic Pressure Test Fluid Pump: Testing and Inspection Main Pump Hydraulic Pressure Test MAIN PUMP HYDRAULIC PRESSURE TEST An accurate pressure test gauge is required. Pressure Gauge C-3293SP has a 0-300 psi range and is used at all locations where the pressures exceed 100 psi. PRESSURE TEST PORT LOCATIONS The pressure ports are located on the upper left hand side of the bellhousing. There is a bolt that has to be removed to access each port. The main pump line pressure is monitored using the bottom port (2). The auxiliary transmission oil pump pressure is monitored using the upper port (1). To determine the line pressure, pressure test adaptor kit 10172 must be used. These tools must be assembled and installed as an assembly onto the transmission, due to accessibility. The pressure port must be accessed through the drivers side fender well. TOOL INSTALLATION 1. Remove the LH front wheel and tire assembly. 2. Remove the LH fender well liner. See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Description and Operation. 3. Remove the main pump access port bolt (2) from the transmission bellhousing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Testing and Inspection > Main Pump Hydraulic Pressure Test > Page 4749 4. Carefully remove the fuel line (1) from the fuel line clip (2). Use caution when installing Pressure Test Adaptor Kit 10172 to the access ports. The threads can be damaged and can cause a leakage in transmission oil. 5. Install the Pressure Test Adaptor 10172 (3) to the main transmission pump. Tighten the banjo bolt (1) to 11 Nm ( 8 ft. lbs). 6. Install the Pressure Gauge C-3293SP onto the Pressure Test Adaptor Kit 10172 (3). CAUTION: If there is no initial line pressure showing on the gauge at start-up, immediately turn the vehicle off. 7. Start the vehicle and verify that the line pressure is at a minimum of 300 kpa (43.5 psi). MAIN TRANSMISSION OIL PUMP PRESSURE TEST PROCEDURE The main transmission oil pump is a variable displacement pump. Pressures can change frequently. Start the engine and bring the transmission temperature up to a minimum of 21°C (70°F). Install the scan tool and verify the temperature. When the correct temperature is reached, check the line pressure reading on the Pressure Gauge C-3293SP. The line pressure should be at a minimum of 300 kpa (43.5 psi). The maximum line pressure should not be greater than 2100 kpa (304 psi). read the estimated transmission line pressure from the Transmission Control Module (TCM). Compare the reading from the gauge, to the estimated line pressure and the table below. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Testing and Inspection > Main Pump Hydraulic Pressure Test > Page 4750 Fluid Pump: Testing and Inspection Auxiliary Pump Hydraulic Pressure Test AUXILIARY PUMP HYDRAULIC PRESSURE TEST An accurate pressure test gauge is required. The Pressure Gauge C-3293SP has a 0-300 psi range and is used at all locations where the pressures exceed 100 psi. PRESSURE TEST PORT LOCATIONS The transmission line pressure ports are located on the upper left hand side of the bellhousing. There are two bolts that has to be removed to access the ports. The main pump line pressure is monitored using the bottom port (2). The auxiliary transmission oil pump pressure is monitored using the upper port (1). To determine the line pressure, pressure test adaptor kit 10172 must be used. These tools must be assembled and installed as an assembly onto the transmission, due to accessibility. The pressure port must be accessed through the drivers side fender well. TOOL INSTALLATION 1. Remove the LH front wheel and tire assembly. 2. Remove the LH fender well liner. See: Body and Frame/Fender/Rear Fender/Rear Fender Liner/Description and Operation. 3. Remove the auxiliary oil pump access port bolt (1) from the transmission bellhousing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Testing and Inspection > Main Pump Hydraulic Pressure Test > Page 4751 4. Carefully remove the fuel line (1) from the fuel line clip (2). NOTE: Use caution when installing Pressure Test Adaptor Kit 10172 to the access ports. The threads can be damaged and can cause a leakage in transmission oil. 5. Install the Pressure Test Adaptor Kit 10172 (3) to the auxiliary pump access port. Tighten the banjo bolt (1) to 11 Nm ( 8 ft. lbs). 6. Install the Pressure Gauge C-3293SP onto the Pressure Test Adaptor Kit 10172 (3) and tighten. AUXILIARY TRANSMISSION OIL PUMP PRESSURE TEST PROCEDURE The 12 Volt battery must be fully charged to perform this test. A battery charger can be used if needed. When testing the auxiliary transmission pump, the engine must not be running. Turn the vehicle to the key on engine off position. Install the scan tool onto the vehicle. Using the scan tool, select HCP and then Miscellaneous Functions. Finally select Transmission Auxiliary Pump Speed (non boost). Choose a pump speed below 80 percent and actuate the transmission auxiliary oil pump. Choosing a pump speed above 80 percent will cause the pressure relief valve to open and will not give an accurate measurement. Watch and record the results on the pressure gauge. Repeat the test at a different pump speed and compare the readings from the gauge, to the estimated line pressure in the table below. The minimum line pressure of the transmission auxiliary oil pump is 414 kpa (60 psi). The maximum line pressure for the auxiliary oil pump is 552 kpa (80 psi). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Testing and Inspection > Main Pump Hydraulic Pressure Test > Page 4752 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Transmission Auxiliary Oil Pump - Removal Fluid Pump: Service and Repair Transmission Auxiliary Oil Pump - Removal REMOVAL WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. 1. Raise and support the vehicle. 2. Place a suitable drain pan. beneath the auxiliary oil pump. 3. Disconnect the transmission auxiliary oil pump electrical connector. 4. Remove the bolt (1) attaching the transmission auxiliary oil pump harness (2) to the transmission bellhousing (3). 5. Remove the four transmission auxiliary oil pump bolts (1) and the auxiliary oil pump. Remove and discard the gasket (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > Transmission Auxiliary Oil Pump - Removal > Page 4755 Fluid Pump: Service and Repair Transmission Auxiliary Oil Pump - Installation INSTALLATION 1. Install a NEW gasket to the transmission auxiliary oil pump. 2. Install the transmission auxiliary oil pump and four bolts. Tighten bolts to 11 Nm (8 ft. lb). 3. Install the bolt (1) attaching the transmission auxiliary oil pump harness (2) to the transmission bellhousing (3). Tighten the bolt (1) to 11 Nm (8 ft. lbs.). 4. Connect the transmission auxiliary oil pump electrical connector. 5. Lower the vehicle. 6. Check the transmission fluid level and fill the transmission with DEXRON(R) VI ATF as necessary. See: Service and Repair/Procedures 7. Using a scan tool, run the transmission auxiliary oil pump for at least one minute to prime the pump. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Tow/Haul Indicator - Description Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator - Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. The tow/haul indicator is located below the minor gauge set on the left side of the cluster. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Tow/Haul Indicator - Description > Page 4761 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator - Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-on message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - self Test - Each time the cluster is put through the self test, the tow/haul indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transmission control system, the PCM, the CCN, the CAN data bus or the electronic communication related to tow/haul indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Tow/Haul Indicator - Description Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator - Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. The tow/haul indicator is located below the minor gauge set on the left side of the cluster. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp > Component Information > Description and Operation > Tow/Haul Indicator - Description > Page 4766 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator - Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-on message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - self Test - Each time the cluster is put through the self test, the tow/haul indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transmission control system, the PCM, the CCN, the CAN data bus or the electronic communication related to tow/haul indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Locations > Page 4770 Overdrive Switch: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SWITCH-TOW/HAUL OVERDRIVE - (INSTRUMENT PANEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Description and Operation > Overdrive Lockout Switch - Description Overdrive Switch: Description and Operation Overdrive Lockout Switch - Description DESCRIPTION The tow/haul on control switch is located in the shift lever arm. The switch is a momentary contact device that signals the Powertrain Control Module (PCM) to toggle current status of the overdrive function. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Description and Operation > Overdrive Lockout Switch - Description > Page 4773 Overdrive Switch: Description and Operation Overdrive Lockout Switch - Operation OPERATION Tow/haul is only used in the D position. When used while towing, the electronic control module (ECU) commands hybrid system to create more positive axle torque to the wheels. When used while coasting downhill and the vehicle gains speed, the ECU commands the hybrid system to create more negative axle torque to the wheels, helping the vehicle to maintain the correct speed. The Powertrain Control Module (PCM) stores a target speed when the accelerator and brake are released, if vehicle speed increases due to a hill, then additional negative wheel torque is added to the PCMs wheel torque request. The Hybrid Control Processor (HCP) follows the PCMs command and downshifts as required to meet the negative torque request. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > Overdrive Lockout Switch - Removal Overdrive Switch: Service and Repair Overdrive Lockout Switch - Removal REMOVAL 1. Using a plastic trim tool (3), remove the tow/haul switch retainer (2) from the gearshift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Service and Repair > Overdrive Lockout Switch - Removal > Page 4776 Overdrive Switch: Service and Repair Overdrive Lockout Switch - Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul switch (3) into the connector (2). 3. Push the tow/haul switch (3) and wiring into the shift lever (1). 4. Install the tow/haul switch retainer onto the shift lever. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description Control Module: Description and Operation Transmission Control Module - Description DESCRIPTION RFE - RLE TRANSMISSIONS The Transmission Control Module (TCM) is a sub-module within the Powertrain Control Module (PCM). The PCM is located on the right inner fender. EVT AHS-T TRANSMISSION TEHCM MOUNTING BOLTS On vehicles equipped with the AHS-T HEV transmission the TCM is imbedded into the Transmission Electronic Hydraulic Control Module (TECHM) that is mounted to the valve body and is not serviceable, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 4785 Control Module: Description and Operation Transmission Control Module - Operation OPERATION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning/TCM Quick Learn BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 4786 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: 42RLE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 4787 545RFE EVT AHS-T SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 4788 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures Control Module: Procedures STANDARD PROCEDURE - RESOLVER LEARN RESOLVER OFFSET LEARN TRIGGER EVT AHS-T TRANSMISSION The Resolver Offset Learn Trigger Procedure requires the use of a scan tool. This program allows the electronic variable transmission (EVT) AHS-T to re-calibrate itself. This will provide the proper transmission operation. The resolver offset learn procedure should be performed if any of the following procedures are performed: - Transmission Assembly Replacement - Transmission Electronic Hydraulic Control Module (TEHCM) Replacement - Flashing the TCM - Electric Motors Replacement - Valve Body Replacement or Recondition To perform the Resolver Offset Learn Trigger Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The shift lever position must stay in PARK until prompted to shift. - The calculated oil temperature must be above 15° C (60° F) and below 93° C (200° F) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4791 Control Module: Removal and Replacement Transmission Control Module - Removal REMOVAL WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. NOTE: If the TECHM is being flashed, removed or replaced, it is necessary to perform the Resolver Offset Learn Trigger procedure using the scan tool. 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove the drain plug, if equipped. 4. Remove the auxiliary oil pump mounting bolts (1). 5. Remove the auxiliary oil pump (2). 6. Remove the transmission oil pan (1), the primary oil filter (2) and the auxiliary oil filter (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4792 7. Lift up the passage sleeve locking tab (1). Remove the passage sleeve by gripping firmly on two ends and pulling the sleeve away. 8. Disconnect the TEHCM 2-way electrical jumper connector (1) from the internal transmission harness. 9. Disconnect the TEHCM electrical connector (1) from the valve body (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4793 10. Remove the TEHCM side mounting bolts (1) and main mounting bolts (2) from the valve body. 11. Disconnect the TEHCM jumper harness. 12. If necessary remove the TECHM filter screen (1). Transmission Control Module - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4794 INSTALLATION WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. NOTE: If the TECHM is being flashed, removed or replaced, it is necessary to perform the Resolver Offset Learn Trigger procedure using the scan tool. 1. Install the filter screen onto the TEHCM. TEHCM JUMPER CONNECTOR 2. Connect the TEHCM jumper harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4795 TEHCM MOUNTING BOLTS 3. Install the TECHM heat sink bolts (1). Tighten the bolts to 7 Nm (62 in.lbs.). 4. Install the TECHM mounting bolts (2). Tighten the bolts to 11 Nm (97 in.lbs.). 5. Connect the 2-way TEHCM electrical connector (1). 6. Connect the TEHCM electrical connector (1) to the valve body. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 4796 NOTE: Orientate the alignment tab inside the passage sleeve with the slot in the electrical connector of the control solenoid valve assembly. Push the sleeve straight into the case bore and connector. Do NOT rotate the sleeve at any time. Ensure the sleeve is fully seated into the case. When the sleeve is properly installed, the distance from the case surface to the end of the sleeve should be 14-16 mm. 7. Lubricate the seals on the passage sleeve with DEXRON(R) VI. Install the passage sleeve (2). Push down on the passage locking tab (1) to secure. NOTE: Using a suitable solvent, clean the oil pan and magnet. 8. Install the auxiliary oil filter assembly (3). 9. Install the primary oil filter assembly (2). 10. Install the oil pan gasket and the oil pan (1) onto the transmission case. Install the oil pan bolts. Tighten the oil pan bolts to 27 Nm (19 ft.lbs.). 11. Install the auxiliary oil pump (2) with a NEW gasket. 12. Install the auxiliary oil pump bolts (1). Tighten the bolts to 11 Nm (97 in.lbs.). 13. Check and fill the transmission as necessary with DEXRON(R) VI transmission fluid. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 4800 Transmission Control System Relay: Diagrams Connector (IN PDC) RELAY-TRANSMISSION CONTROL (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Seal - Removal Seals and Gaskets: Service and Repair Seal - Removal REMOVAL FRONT HUB SEAL 1. Remove the transmission from the vehicle. See: Service and Repair/Removal and Replacement/Removal. NOTE: For ease of removal, install two M10x1.5 in. bolts into the damper. Grasp the bolts while removing. 2. Remove the transmission damper (1) from the transmission (2) by pulling the damper until the center hub clears the oil pump seal. 3. Remove the front seal snap ring (1) from the damper housing (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Seal - Removal > Page 4805 4. Using a suitable pry tool (1) , remove the front seal (2). REAR OUTPUT SHAFT SEAL 1. Remove the transfer case from the vehicle.See: Service and Repair/Removal and Replacement/Removal. 2. Using a suitable pry tool, remove the rear output shaft seal (1) from the extension housing (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Seal - Removal > Page 4806 Seals and Gaskets: Service and Repair Seal - Installation INSTALLATION FRONT HUB SEAL 1. Clean the seal bore in the damper/oil pump housing of any residue or particles remaining from the original seal. 2. Using Seal Installer 10154 (1), install a new input shaft oil seal (2). 3. Install the front seal snap ring (1) to the damper housing (2). 4. Install the transmission damper (1) to the damper housing (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Seal - Removal > Page 4807 5. Check damper seating with Gage Bar 6311 (1) and straightedge (2). Surface of damper should be at least 26mm (1.02 in.) to the straightedge when damper is fully seated. 6. Install the transmission into the vehicle. See: Service and Repair/Removal and Replacement/Installation. REAR OUTPUT SHAFT SEAL 1. Using seal installer Seal Installer C-3860-A (1), install a new rear output shaft seal (2). 2. Install the transfer case into the vehicle.See: Transfer Case/Service and Repair/Removal and Replacement/MP3010 Transfer Case - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4812 Fluid Pressure Sensor/Switch: Diagrams Connector (4.7L/5.7L) - (ENGINE) 4 WAY SENSOR-LINE PRESSURE (4.7L/5.7L) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Locations > Page 4816 Overdrive Switch: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SWITCH-TOW/HAUL OVERDRIVE - (INSTRUMENT PANEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Overdrive Lockout Switch Description Overdrive Switch: Description and Operation Overdrive Lockout Switch - Description DESCRIPTION The tow/haul on control switch is located in the shift lever arm. The switch is a momentary contact device that signals the Powertrain Control Module (PCM) to toggle current status of the overdrive function. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Overdrive Lockout Switch Description > Page 4819 Overdrive Switch: Description and Operation Overdrive Lockout Switch - Operation OPERATION Tow/haul is only used in the D position. When used while towing, the electronic control module (ECU) commands hybrid system to create more positive axle torque to the wheels. When used while coasting downhill and the vehicle gains speed, the ECU commands the hybrid system to create more negative axle torque to the wheels, helping the vehicle to maintain the correct speed. The Powertrain Control Module (PCM) stores a target speed when the accelerator and brake are released, if vehicle speed increases due to a hill, then additional negative wheel torque is added to the PCMs wheel torque request. The Hybrid Control Processor (HCP) follows the PCMs command and downshifts as required to meet the negative torque request. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Overdrive Lockout Switch - Removal Overdrive Switch: Service and Repair Overdrive Lockout Switch - Removal REMOVAL 1. Using a plastic trim tool (3), remove the tow/haul switch retainer (2) from the gearshift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Overdrive Lockout Switch - Removal > Page 4822 Overdrive Switch: Service and Repair Overdrive Lockout Switch - Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul switch (3) into the connector (2). 3. Push the tow/haul switch (3) and wiring into the shift lever (1). 4. Install the tow/haul switch retainer onto the shift lever. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4826 Transmission Position Switch/Sensor: Diagrams Connector (HEV) - (TRANSMISSION SIDE) 12 WAY SENSOR-TRANSMISSION RANGE (HEV) - (TRANSMISSION SIDE) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Description DESCRIPTION The transmission range sensor (2) is located inside the transmission and connects to the mainshaft (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description > Page 4829 Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body. See: Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Disconnect the transmission range sensor electrical connector (1). 3. Remove the bolt (1) securing the transmission range sensor (2) to the mainshaft (3). 4. Remove the mainshaft roll pin (1) from the transmission case (2) and remove the mainshaft. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4832 5. Lower the transmission range sensor (2) and remove the park actuator rod (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4833 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install the park actuator rod (3) into the transmission range sensor (2). 2. Install the mainshaft roll pin (1) to the transmission case (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4834 3. Position the transmission range sensor (2) into place in the transmission case. 4. Install the mainshaft (3) into the transmission case. 5. Install the transmission range sensor mounting bolt. Tighten the bolt to 8 Nm (71 NOTE: Before install the TEHCM / valve body assembly to the transmission case, be certain the existing gasket is in place. 6. Install the valve body. See: Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 4839 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 4840 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way Transmission Speed Sensor: Diagrams Input Speed Sensor (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-INPUT SPEED - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way > Page 4843 Transmission Speed Sensor: Diagrams Output Speed Sensor (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-OUTPUT SPEED - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way > Page 4844 Transmission Speed Sensor: Diagrams Output Speed Sensor (HEV) Engine 2 Way Connector (HEV) - ENGINE 2 WAY SENSOR-OUTPUT SPEED (HEV) - ENGINE 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Oil Temperature Sensor - Description Transmission Temperature Sensor/Switch: Description and Operation Transmission Oil Temperature Sensor - Description DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Electronic Hydraulic Control Module (TEHCM). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Oil Temperature Sensor - Description > Page 4849 Transmission Temperature Sensor/Switch: Description and Operation Transmission Oil Temperature Sensor - Operation OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature. - Engine coolant temperature. - In-gear run time since start-up. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4854 Shift Interlock Solenoid: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK - (INSTRUMENT PANEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > Transmission Shifter - Description Shifter A/T: Description and Operation Transmission Shifter - Description DESCRIPTION The gear shift mechanism provides six shift positions which are: - Park (P) - Reverse (R) - Neutral (N) - Drive (D) - Manual second (2) - Manual low (1) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Description and Operation > Transmission Shifter - Description > Page 4862 Shifter A/T: Description and Operation Transmission Shifter - Operation OPERATION MANUAL LOW (1) range provides FIRST gear only. Overrun braking is also provided in this range. MANUAL SECOND (2) range provides FIRST and SECOND gear only. DRIVE range provides FIRST, SECOND, THIRD and FOURTH gear ranges. No further movement of the shift mechanism is required to complete the 2-3 or the 3-4 shifts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection Shift Cable: Testing and Inspection DIAGNOSIS AND TESTING - GEARSHIFT CABLE 1. Engine starts must be possible with shift lever in PARK or NEUTRAL positions only. Engine starts must not be possible in any other gear position. 2. With the shift lever in the: a. PARK position - Apply upward force on the shift arm and remove pressure. Engine starts must be possible. b. PARK position - Apply downward force on the shift arm and remove pressure. Engine starts must be possible. c. NEUTRAL position - Normal position. Engine starts must be possible. d. NEUTRAL position - Engine running and brakes applied, apply upward force on the shift arm. Transmission shall not be able to shift from neutral to reverse. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Testing and Inspection > Page 4867 Shift Cable: Adjustments ADJUSTMENTS - GEARSHIFT CABLE NOTE: Always run the shift lever test using the scan tool to help diagnose a potential TRS problem Check adjustment by starting the engine in PARK and NEUTRAL. Adjustment is CORRECT if the engine starts only in these positions. Adjustment is INCORRECT if the engine starts in one but not both positions. If the engine starts in any position other than PARK or NEUTRAL, or if the engine will not start at all, the transmission range sensor may be faulty. Gearshift Adjustment Procedure 1. Shift transmission into PARK. 2. Release cable adjuster lock tab (3) (underneath the steering column) to unlock cable. 3. Raise vehicle. 4. Disengage the cable eyelet from the transmission manual shift lever. 5. Verify transmission shift lever is in PARK detent by moving lever fully rearward. Last rearward detent is PARK position. 6. Verify positive engagement of transmission park lock by attempting to rotate propeller shaft. Shaft will not rotate when park lock is engaged. 7. Snap the cable eyelet onto the transmission manual shift lever. 8. Lower vehicle. 9. Lock shift cable by pressing cable adjuster lock tab (3) downward until it snaps into place. 10. Check engine starting. Engine should start only in PARK and NEUTRAL. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Gearshift Cable - Removal Shift Cable: Service and Repair Gearshift Cable - Removal REMOVAL 1. Shift transmission into PARK. 2. Raise vehicle. 3. Disengage cable (1) eyelet at transmission manual shift lever (2) and pull cable adjuster out of mounting bracket (3) by pinching the locking tabs together. 4. Lower the vehicle. 5. Remove the dash panel insulation pad as necessary to access the gearshift cable grommet (2). 6. Remove grommet (2) from the dash panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Gearshift Cable - Removal > Page 4870 7. Remove any steering column (1) trim necessary to access the gearshift cable (2) and BTSI mechanism. 8. Disconnect the BTSI wiring connector (5). 9. Disconnect cable at lower column bracket and shift lever pin and pull the cable through the dash panel opening into the vehicle. 10. Remove gearshift cable (2) from vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Gearshift Cable - Removal > Page 4871 Shift Cable: Service and Repair Gearshift Cable - Installation INSTALLATION 1. Route the transmission end of the gearshift cable (1) through the opening in the dash panel. 2. Seat the cable grommet (2) into the dash panel opening. 3. Snap the cable into the steering column (1) bracket so the retaining ears are engaged and snap the cable eyelet onto the shift lever ball stud. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Service and Repair > Gearshift Cable - Removal > Page 4872 4. Raise the vehicle. 5. Place the transmission manual shift lever in the "PARK" detent position and rotate prop shaft to ensure transmission is in PARK. 6. Route the gearshift cable through the transmission mounting bracket (3) and secure the cable by snapping the cable retaining tabs into the transmission bracket and snapping the cable eyelet (1) on the manual shift lever ball stud (2). 7. Lower vehicle. 8. Lock the shift cable adjustment by pressing the cable adjuster lock tab (3) downward until it snaps into place. 9. Check for proper operation of the transmission range sensor. 10. Adjust the gearshift cable as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter: > 21-022-08 > Oct > 08 > A/T - Converter Shudder On Vehicles With Less Than 4K Mi Torque Converter: Customer Interest A/T - Converter Shudder On Vehicles With Less Than 4K Mi NUMBER: 21-022-08 GROUP: Transmission DATE: October 8, 2009 SUBJECT: Torque Convertor Shudder On Vehicles With Less Then 4000 Miles OVERVIEW: This bulletin involves using the StarSCAN(R) to verify that the "Torque Converter Break In" option is disabled (status = false). MODELS: 2009 (DS) Ram Truck 2009 (HB) Durango 2009 (JK) Wrangler 2009 (KA) Nitro 2009 (KA) Nitro (International Markets) 2009 (K1) Cherokee (CKD) 2009 (KK) Liberty 2009 (KK) Liberty (International Markets) 2009 (LC) Challenger 2009 (LE) 300C/300 Touring (International Markets) 2009 (L2) 300 (China) 2009 (LX) 300/Magnum/Charger 2009 (ND) Dakota NOTE: This Bulletin applies to DS/JK/LX/LE/LC/HB/KA/KK/K1 and ND models equipped with a 42 RLE transmission (Sales Code DGV) built before September 29, 2008 (0929XX MDH) or L2 models built with a 42 RLE transmission (Sales Code DGV) built before October 10, 2008 (1010XX MDH). SYMPTOM/CONDITION: Some customers may experience a shudder condition within the first 4000 miles. This shudder happens during steady state driving with the torque convertor in partial lock while the transmission is still in torque converter break in mode. The shudder feels like the vehicle is being driven over rumble strips. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine and transmission Systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced or can be verified, perform the Repair Procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest for Torque Converter: > 21-022-08 > Oct > 08 > A/T - Converter Shudder On Vehicles With Less Than 4K Mi > Page 4881 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Using the StarSCAN(R) select PCM. 2. Read DTC from the PCM. 3. Are any PCM DTC present? a. No >>> proceed to Step # 4 b. Yes >>> Repair DTC as necessary then proceed to Step # 4 4. Select the "Misc Functions Menu" on the StarSCAN(R). 5. Select the "TCC Break In" option. 6. Select "Start" and the select "Next" 7. Select "View Current TCC Break-In Status" 8. Is the "Torque Converter Break In Complete status False? a. Yes >>> Using the StarSCAN(R) disable "Torque Converter Break-In" b. No >>> This bulletin does not apply, further diagnosis is required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 21-022-08 > Oct > 08 > A/T - Converter Shudder On Vehicles With Less Than 4K Mi Torque Converter: All Technical Service Bulletins A/T - Converter Shudder On Vehicles With Less Than 4K Mi NUMBER: 21-022-08 GROUP: Transmission DATE: October 8, 2009 SUBJECT: Torque Convertor Shudder On Vehicles With Less Then 4000 Miles OVERVIEW: This bulletin involves using the StarSCAN(R) to verify that the "Torque Converter Break In" option is disabled (status = false). MODELS: 2009 (DS) Ram Truck 2009 (HB) Durango 2009 (JK) Wrangler 2009 (KA) Nitro 2009 (KA) Nitro (International Markets) 2009 (K1) Cherokee (CKD) 2009 (KK) Liberty 2009 (KK) Liberty (International Markets) 2009 (LC) Challenger 2009 (LE) 300C/300 Touring (International Markets) 2009 (L2) 300 (China) 2009 (LX) 300/Magnum/Charger 2009 (ND) Dakota NOTE: This Bulletin applies to DS/JK/LX/LE/LC/HB/KA/KK/K1 and ND models equipped with a 42 RLE transmission (Sales Code DGV) built before September 29, 2008 (0929XX MDH) or L2 models built with a 42 RLE transmission (Sales Code DGV) built before October 10, 2008 (1010XX MDH). SYMPTOM/CONDITION: Some customers may experience a shudder condition within the first 4000 miles. This shudder happens during steady state driving with the torque convertor in partial lock while the transmission is still in torque converter break in mode. The shudder feels like the vehicle is being driven over rumble strips. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine and transmission Systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced or can be verified, perform the Repair Procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Torque Converter: > 21-022-08 > Oct > 08 > A/T - Converter Shudder On Vehicles With Less Than 4K Mi > Page 4887 SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: 1. Using the StarSCAN(R) select PCM. 2. Read DTC from the PCM. 3. Are any PCM DTC present? a. No >>> proceed to Step # 4 b. Yes >>> Repair DTC as necessary then proceed to Step # 4 4. Select the "Misc Functions Menu" on the StarSCAN(R). 5. Select the "TCC Break In" option. 6. Select "Start" and the select "Next" 7. Select "View Current TCC Break-In Status" 8. Is the "Torque Converter Break In Complete status False? a. Yes >>> Using the StarSCAN(R) disable "Torque Converter Break-In" b. No >>> This bulletin does not apply, further diagnosis is required. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control System Relay, A/T > Component Information > Locations > Page 4891 Transmission Control System Relay: Diagrams Connector (IN PDC) RELAY-TRANSMISSION CONTROL (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Description and Operation Transmission Cooler: Description and Operation DESCRIPTION The transmission oil cooler (2) is an oil to air type cooler. The cooler (2) is located in front of the radiator (1) behind the power steering cooler (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > TPIM/Transmission Oil Cooler - Removal Transmission Cooler: Service and Repair TPIM/Transmission Oil Cooler - Removal COMBINATION TPIM/TRANSMISSION OIL COOLER WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Perform HEV specific high voltage power down and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Disconnect the negative battery cable. CAUTION: Disconnecting the 12 V battery from the vehicle within two minutes of the last ignition key transition from Off to Run may cause a Battery Pack Control Module (BPCM) State Of Charge (SOC) mismatch. 3. Drain the TPIM cooling system. See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/TPIM Cooling System Draining 4. Remove the coolant pump.See: Engine, Cooling and Exhaust/Cooling System/Water Pump/Service and Repair/Removal and Replacement/TPIM Coolant Pump - Removal 5. Using Tool 9005, disconnect the transmission cooler lines (4). 6. Unclip the cooler lines (3) at radiator. 7. Disconnect the temperature sensor electrical connector. 8. Remove the coolant hose. 9. Remove the upper cooler mounting bolts. 10. Remove the upper cooler mounting bolts. 11. Remove the lower cooler mounting bolts. 12. Remove the Combination TPIM/Transmission Oil Cooler from bottom of the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > TPIM/Transmission Oil Cooler - Removal > Page 4897 Transmission Cooler: Service and Repair TPIM/Transmission Oil Cooler - Installation COMBINATION TPIM/TRANSMISSION OIL COOLER WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. If removed, install the TPIM coolant temperature sensor. Tighten to 20 Nm (177 in. lbs.) 2. Position the Transmission/TPIM cooler. 3. Install the upper mounting bolts. 4. Install the lower mounting bolts 5. Tighten bolts to 8.5 Nm (75 in. lbs.). 6. Clip the transmission tubes (3) into the retainers (2) on bottom of the radiator. 7. Install the transmission cooler lines (4) onto the cooler tubes (3). 8. Install the coolant hose. 9. Connect the temperature sensor electrical connector. 10. Install the coolant pump See: Engine, Cooling and Exhaust/Cooling System/Water Pump/Service and Repair/Removal and Replacement/TPIM Coolant Pump - Installation 11. Fill the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair/Cooling System Filling 12. Connect negative battery cable. 13. Perform HEV specific high voltage power up and high voltage isolation check safety procedures. See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > TPIM/Transmission Oil Cooler - Removal > Page 4898 Transmission Cooler: Service and Repair Removal REMOVAL 1. Remove the pushpins (1) and the upper condenser/radiator seal (2). 2. Remove the upper transmission cooler mounting bolt. 3. Raise the vehicle. 4. Disconnect the transmission cooler lines (1). 5. Remove the lower transmission cooler mounting bolts. 6. Remove the transmission cooler from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > TPIM/Transmission Oil Cooler - Removal > Page 4899 Transmission Cooler: Service and Repair Installation INSTALLATION 1. Position the transmission cooler in the vehicle. 2. Install the lower transmission cooler mounting bolt. Tighten to 10 Nm (90 in. lbs.) 3. Connect the transmission cooler lines. 4. Lower the vehicle. 5. Install the upper transmission cooler mounting bolt. Tighten bolt to 10 Nm (90 in. lbs.). 6. Install the upper condenser/radiator seal. 7. Check the transmission fluid level , , and See: Service and Repair/Procedures. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4903 Transmission Position Switch/Sensor: Diagrams Connector (HEV) - (TRANSMISSION SIDE) 12 WAY SENSOR-TRANSMISSION RANGE (HEV) - (TRANSMISSION SIDE) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Description DESCRIPTION The transmission range sensor (2) is located inside the transmission and connects to the mainshaft (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description > Page 4906 Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body. See: Valve Body/Service and Repair/Removal and Replacement/Valve Body - Removal. 2. Disconnect the transmission range sensor electrical connector (1). 3. Remove the bolt (1) securing the transmission range sensor (2) to the mainshaft (3). 4. Remove the mainshaft roll pin (1) from the transmission case (2) and remove the mainshaft. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4909 5. Lower the transmission range sensor (2) and remove the park actuator rod (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4910 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install the park actuator rod (3) into the transmission range sensor (2). 2. Install the mainshaft roll pin (1) to the transmission case (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 4911 3. Position the transmission range sensor (2) into place in the transmission case. 4. Install the mainshaft (3) into the transmission case. 5. Install the transmission range sensor mounting bolt. Tighten the bolt to 8 Nm (71 NOTE: Before install the TEHCM / valve body assembly to the transmission case, be certain the existing gasket is in place. 6. Install the valve body. See: Valve Body/Service and Repair/Removal and Replacement/Valve Body - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 4916 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 4917 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way Transmission Speed Sensor: Diagrams Input Speed Sensor (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-INPUT SPEED - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way > Page 4920 Transmission Speed Sensor: Diagrams Output Speed Sensor (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-OUTPUT SPEED - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way > Page 4921 Transmission Speed Sensor: Diagrams Output Speed Sensor (HEV) Engine 2 Way Connector (HEV) - ENGINE 2 WAY SENSOR-OUTPUT SPEED (HEV) - ENGINE 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Oil Temperature Sensor - Description Transmission Temperature Sensor/Switch: Description and Operation Transmission Oil Temperature Sensor - Description DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Electronic Hydraulic Control Module (TEHCM). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Oil Temperature Sensor - Description > Page 4926 Transmission Temperature Sensor/Switch: Description and Operation Transmission Oil Temperature Sensor - Operation OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature. - Engine coolant temperature. - In-gear run time since start-up. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Electrohydraulic Control Module C1 (HEV) (Transmission Side) 6 Way Valve Body: Diagrams Electrohydraulic Control Module C1 (HEV) (Transmission Side) 6 Way Connector C1 (HEV) - (TRANSMISSION SIDE) 6 WAY MODULE-ELECTROHYDRAULIC CONTROL (HEV) - (TRANSMISSION SIDE) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > Electrohydraulic Control Module C1 (HEV) (Transmission Side) 6 Way > Page 4931 Valve Body: Diagrams Electrohydraulic Control Module C2 (HEV) (Transmission Side) 3 Way Connector C2 (HEV) - (TRANSMISSION SIDE) 3 WAY MODULE-ELECTROHYDRAULIC CONTROL (HEV) - (TRANSMISSION SIDE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement Valve Body: Removal and Replacement Valve Body - Removal REMOVAL WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. NOTE: If the TEHCM is being flashed, removed or replaced, it is necessary to perform the Resolver Offset Learn Trigger procedure. Use the scan tool and perform the Resolver Offset Learn Trigger procedure NOTE: If replacing the TEHCM, the VIN will need to be programmed using a scan tool. 1. Raise and support the vehicle. 2. Place a suitable drain pan. beneath the auxiliary oil pump. 3. Disconnect the transmission auxiliary oil pump electrical connector. 4. Remove the bolt (1) attaching the transmission auxiliary oil pump harness (2) to the transmission bellhousing (3). 5. Remove the four transmission auxiliary oil pump bolts (1) and the auxiliary oil pump (2). 6. Remove and discard the transmission auxiliary oil pump gasket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4934 7. Remove the transmission oil pan bolts and remove the transmission oil pan (1), the primary oil filter (2) and the auxiliary oil filter (3). 8. Disengage the passage sleeve locking tab (1), and remove the passage sleeve. 9. Disconnect the TEHCM 2-way electrical jumper connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4935 10. Disconnect the TEHCM electrical connector (1) from the valve body (2). 11. Remove the six valve body-to-transmission case mounting bolts (1) 12. Remove the valve body (2) from the transmission case (3) and if necessary, remove the valve body-to-transmission case seals (1). Valve Body - Installation INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4936 WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. NOTE: If the TECHM is being flashed, removed or replaced, it is necessary to use the scan tool and perform the Resolver Offset Learn Trigger procedure. 1. If necessary install the valve body- to- transmission case seals (1). Install the valve body (2) to the transmission case (3). 2. Install the six valve body- to-transmission case mounting bolts (1). Tighten the bolts to 11 Nm (97 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4937 3. Connect the TEHCM electrical connector (1) to the valve body (2). 4. Connect the TEHCM 2-way electrical jumper connector (1). NOTE: Orientate the alignment tab inside the passage sleeve with the slot in the electrical connector of the control solenoid valve assembly. Engage the sleeve straight into the case bore and connector. Do not rotate the sleeve at any time. Make sure the sleeve is fully seated into the case. When the sleeve is properly installed, the distance from the case surface to the end of the sleeve should be 14-16 mm (0.55-0.63 in.). 5. Lubricate the seals on the passage sleeve with DEXRON(R) VI and install the passage sleeve. 6. Push up on the passage sleeve locking tab (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4938 7. Install the primary oil filter (2), the auxiliary oil filter (3) and the transmission oil pan (1), 8. Install the transmission oil pan bolts. Tighten the oil pan bolts to 27 Nm (20 ft. lbs.). 9. Install a new gasket to the transmission auxiliary oil pump (2). 10. 10. Install the transmission auxiliary oil pump and four bolts. Tighten bolts to 11 Nm (8 ft. lb). 11. Install the bolt (1) attaching the transmission auxiliary oil pump harness (2) to the transmission bellhousing (3). Tighten the bolt to 11 Nm (8 ft. lbs) 12. Connect the transmission auxiliary oil pump electrical connector. 13. Lower the vehicle. 14. Check and fill the transmission with DEXRON(R) VI ATF as necessary. . See: Service and Repair/Procedures/Transmission Fill Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4939 Valve Body: Overhaul Valve Body - Disassembly DISASSEMBLY 1. Remove the detent spring mounting bolt (1) and the detent spring (2). 2. Remove the TEHCM heat sink bolts (1) and mounting and valve body bolts (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4940 3. Remove the TEHCM filter screen (1) from the TEHCM (2). 4. Remove the upper valve body bolts (1). 5. Separate the upper valve body (2) from the separator plate (4) and the lower valve body (5). NOTE: For ease of installation, identify the location of all the check balls. 6. Remove the check balls (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4941 7. Remove the damper control retainer, plug, valve and spring (1). 8. Remove the pressure control solenoid 2 retainer, plug, valve and spring (2). 9. Remove pressure control solenoid 4 retainer , plug, valve and spring (3). 10. Remove the clutch select solenoid retainer, plug, valve and spring (4). 11. Remove the regulator actuator feed retainer, spring and valve (5). 12. Remove the pressure control solenoid 3 retainer, spring and valve (6). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4942 13. Remove the pressure control solenoid 3 retainer, plug, valve and spring (1). 14. Remove the boost pressure control solenoid 3 retainer, spring and valve (2). 15. Remove the relief backfill plug, spring and ball (3). Valve Body - Cleaning CLEANING The use of a crocus cloth is permissible where necessary, providing it is used carefully. When using on shafts or valves, use extreme care to avoid rounding off sharp edges. Sharp edges are vital, as they prevent foreign matter from getting between the valve and valve bore. Do not reuse snap rings or e-clips that are bent or distorted. Lubricate transmission parts with DEXRON(R) VI automatic transmission fluid during overhaul and assembly. Use petroleum jelly, Mopar(R) Door Ease, or Ru-Glyde to prelubricate seals, o-rings and thrust washers. Petroleum jelly can also be used to hold parts in place during reassembly. Flush the valve body bores and fluid passages thoroughly with solvent. Dry all the fluid passages with compressed air. Be sure all solvent is removed from the valve body and that all fluid passages are clear. NOTE: Do not use shop towels, rags or any other transmission component unless they are made from lint free materials to dry the case. Lint sticks to case surfaces and transmission components and circulate throughout the transmission after assembly. A sufficient quantity of lint can block fluid passages and interfere with valve body operation. Valve Body - Inspection INSPECTION Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straightedge to check surface flatness. Minor scratches may be removed with crocus cloth using very light pressure. Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass, or equally flat surface. If distortion is severe, or any surfaces are heavily scored, the valve body will have to be Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4943 replaced. Inspect the valves and plugs for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth. Do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore. Inspect all of the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage, or broken coils. Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores. Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in handling. Inspect all the fluid seals (1) in the transmission case. Replace any seals that are cracked, distorted, or damaged in any way. These seals pass fluid pressure directly to the clutches. Any pressure leak at these points may cause transmission performance problems. Valve Body - Assembly ASSEMBLY NOTE: Lubricate all the valve body valves in clean DEXRON(R) VI ATF before final assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4944 1. Install the pressure control solenoid 3 retainer, plug valve and spring (1). 2. Install the boost pressure control solenoid 3 retainer spring and valve (2). 3. Install the relief backfill plug, spring and ball (3). 4. Install the damper control retainer, plug, valve and spring (1). 5. Install the pressure control solenoid 2 retainer, plug, valve and spring (2). 6. Install the pressure control solenoid 4 retainer , plug, valve and spring (3). 7. Install the clutch select solenoid retainer, plug valve and spring (4). 8. Install the regulator actuator feed retainer, spring and valve (5). 9. Install the pressure control solenoid 3 retainer, spring and valve (6). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4945 10. Install the check balls (3). 11. Install the upper valve body (2) onto the separator plate (4) and the lower valve body (5). 12. Install the upper valve body bolts (1). Tighten the bolts to 11 Nm (8 ft lbs). 13. Install the TEHCM filter screen (1) to the TEHCM (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Replacement > Page 4946 14. Install the TEHCM heat sink bolts (1). Tighten the bolts to 7 Nm (5 ft. lbs.). 15. Install the TEHCM mounting and valve body bolts (2). Tighten the bolts to 11 Nm (8 ft lbs). 16. Install the detent spring (2) and the mounting bolt (1), Tighten the bolt to 7 Nm (5 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 21-008-09 > Nov > 09 > Electrical - MIL ON/DTC P0A2D Set Wiring Harness: Customer Interest Electrical - MIL ON/DTC P0A2D Set NUMBER: 21-008-09 GROUP: Transmission DATE: November 10, 2009 WiTech, StarSCAN(R), StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY BE USED TO PERFORM THIS OPERATION. SUBJECT: MIL Illumination Due to POA2D OVERVIEW: This bulletin involves inspecting a body harness connector at the transmission and replacing a harness within the transmission. MODELS: 2009 (HB) Duragno 2009 (HG) Aspen NOTE: This bulletin applies to vehicles equipped with 5.7L HEV Engine (Sales code HEH) SYMPTOM/CONDITION: Customers may experience intermittent MIL Illumination. No other symptoms will be noted or experienced. Further investigation by the technician may find DTC P0A2D - Drive Motor A Temperature Sensor 1 Circuit High. DIAGNOSIS: Using a Scan Tool with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. 1. Perform High Voltage Power Down Procedure. Refer to DealerCONNECT > TechCONNECT > Service Info > 08 - Electrical > 8F - Engine Systems > Battery System > Standard Procedure > High Voltage Power Down. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 21-008-09 > Nov > 09 > Electrical - MIL ON/DTC P0A2D Set > Page 4955 2. Perform High Voltage Isolation Check Procedure. Refer to DealerCONNECT > TechCONNECT > Service Info > 08 - Electrical > 8F - Engine Systems > Battery System > Standard Procedure > High Voltage Isolation Check. 3. Raise vehicle on a suitable hoist. 4. Disconnect and isolate the Low Voltage (12 Volt) battery negative cable: a. Remove battery tray side mounting bolt to frame, on the front side of the tray and install the removed bolt in the threaded hole in the frame through the slotted hole in the battery tray. Snug the bolt then loosen 1 or 2 turns. b. Remove battery tray side mounting bolt to frame, on the rear side of the tray and install the removed bolt in the threaded hole in the frame through the slotted hole in the battery tray. Snug the bolt then loosen 1 or 2 turns. c. Remove the battery tray bottom mount bolt while supporting the battery tray and lower tray to gain access to battery cables. 5. Disconnect and Inspect the body side of the 24 pin connector for damage or terminals pushed out as follows: a. Remove the heat shield at the right rear of transmission. b. Remove both the black and tan connectors from the transmission. 6. Inspect the body side of the harness for damage to the terminals. Are female terminal(s) damaged in body side of the connector? a. Yes >> Proceed to Step # 7. b. No >> Proceed to Step # 9. 7. Replace damaged terminals in the body side of the connector using terminals supplied in the parts kit, p/n 68066717AA, and following wire splicing procedures available in DealerCONNECT > TechCONNECT under: Wiring > 8W-01 Wiring Diagram Information > Wire > Standard Procedure > Wire Splicing. 8. Inspect the plastic connector body. Is Plastic connector body damaged to due improper pin alignment? a. Yes >> Replace Connector body. Transfer one wire at a time from the old connector to the new connector. Ensure terminals snap fully into connector. Check by lightly pulling on each wire. Continue with Step # 9. b. No >> Continue with Step # 9. 9. Remove the auxiliary pump mounting bolts. Several ounces of fluid may drip. Wrap the pump with a clean towel and tie out of the way. Do not hang by wiring. NOTE: In the following step, ensure drain pan is totally clean. Fluid is to be reused. 10. Replace transmission internal wiring harness. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 21 - Transmission and Transfer Case > Automatic - EVI > WIRING HARNESS, Internal Transmission > Removal. 11. Install replacement harness, pn 68049835AB. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 21 - Transmission and Transfer Case > Automatic - EVT > WIRING HARNESS, Internal Transmission > Installation. 12. Fill transmission to the proper level using DEXRON(R) VI, pn 68043742AA only. Refer to the detailed service information available in DealerCONNECT > TechCONNECT under: Service Info > 21 - Transmission and Transfer Case > Automatic - EVT > FLUID > TRANSMISSION FILL and FLUID LEVEL CHECK. CAUTION: Do NOT use MS-9602 Fluid in the HEV transmission. POLICY: Reimbursable within the provisions of the warranty. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 21-008-09 > Nov > 09 > Electrical - MIL ON/DTC P0A2D Set > Page 4956 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 21-008-09 > Nov > 09 > Electrical - MIL ON/DTC P0A2D Set Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC P0A2D Set NUMBER: 21-008-09 GROUP: Transmission DATE: November 10, 2009 WiTech, StarSCAN(R), StarMOBILE DESKTOP CLIENT -OR- StarMOBILE STANDALONE MODE MAY BE USED TO PERFORM THIS OPERATION. SUBJECT: MIL Illumination Due to POA2D OVERVIEW: This bulletin involves inspecting a body harness connector at the transmission and replacing a harness within the transmission. MODELS: 2009 (HB) Duragno 2009 (HG) Aspen NOTE: This bulletin applies to vehicles equipped with 5.7L HEV Engine (Sales code HEH) SYMPTOM/CONDITION: Customers may experience intermittent MIL Illumination. No other symptoms will be noted or experienced. Further investigation by the technician may find DTC P0A2D - Drive Motor A Temperature Sensor 1 Circuit High. DIAGNOSIS: Using a Scan Tool with the appropriate Diagnostic Procedures available in TechCONNECT, verify all engine systems are functioning as designed. If DTC's other than those listed above are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above symptom/condition is experienced, perform the Repair Procedure. PARTS REQUIRED: SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE: WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. 1. Perform High Voltage Power Down Procedure. Refer to DealerCONNECT > TechCONNECT > Service Info > 08 - Electrical > 8F - Engine Systems > Battery System > Standard Procedure > High Voltage Power Down. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 21-008-09 > Nov > 09 > Electrical - MIL ON/DTC P0A2D Set > Page 4962 2. Perform High Voltage Isolation Check Procedure. Refer to DealerCONNECT > TechCONNECT > Service Info > 08 - Electrical > 8F - Engine Systems > Battery System > Standard Procedure > High Voltage Isolation Check. 3. Raise vehicle on a suitable hoist. 4. Disconnect and isolate the Low Voltage (12 Volt) battery negative cable: a. Remove battery tray side mounting bolt to frame, on the front side of the tray and install the removed bolt in the threaded hole in the frame through the slotted hole in the battery tray. Snug the bolt then loosen 1 or 2 turns. b. Remove battery tray side mounting bolt to frame, on the rear side of the tray and install the removed bolt in the threaded hole in the frame through the slotted hole in the battery tray. Snug the bolt then loosen 1 or 2 turns. c. Remove the battery tray bottom mount bolt while supporting the battery tray and lower tray to gain access to battery cables. 5. Disconnect and Inspect the body side of the 24 pin connector for damage or terminals pushed out as follows: a. Remove the heat shield at the right rear of transmission. b. Remove both the black and tan connectors from the transmission. 6. Inspect the body side of the harness for damage to the terminals. Are female terminal(s) damaged in body side of the connector? a. Yes >> Proceed to Step # 7. b. No >> Proceed to Step # 9. 7. Replace damaged terminals in the body side of the connector using terminals supplied in the parts kit, p/n 68066717AA, and following wire splicing procedures available in DealerCONNECT > TechCONNECT under: Wiring > 8W-01 Wiring Diagram Information > Wire > Standard Procedure > Wire Splicing. 8. Inspect the plastic connector body. Is Plastic connector body damaged to due improper pin alignment? a. Yes >> Replace Connector body. Transfer one wire at a time from the old connector to the new connector. Ensure terminals snap fully into connector. Check by lightly pulling on each wire. Continue with Step # 9. b. No >> Continue with Step # 9. 9. Remove the auxiliary pump mounting bolts. Several ounces of fluid may drip. Wrap the pump with a clean towel and tie out of the way. Do not hang by wiring. NOTE: In the following step, ensure drain pan is totally clean. Fluid is to be reused. 10. Replace transmission internal wiring harness. Refer to the detailed removal procedures available in DealerCONNECT > TechCONNECT under: Service Info > 21 - Transmission and Transfer Case > Automatic - EVI > WIRING HARNESS, Internal Transmission > Removal. 11. Install replacement harness, pn 68049835AB. Refer to the detailed installation procedures available in DealerCONNECT > TechCONNECT under: Service Info > 21 - Transmission and Transfer Case > Automatic - EVT > WIRING HARNESS, Internal Transmission > Installation. 12. Fill transmission to the proper level using DEXRON(R) VI, pn 68043742AA only. Refer to the detailed service information available in DealerCONNECT > TechCONNECT under: Service Info > 21 - Transmission and Transfer Case > Automatic - EVT > FLUID > TRANSMISSION FILL and FLUID LEVEL CHECK. CAUTION: Do NOT use MS-9602 Fluid in the HEV transmission. POLICY: Reimbursable within the provisions of the warranty. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 21-008-09 > Nov > 09 > Electrical - MIL ON/DTC P0A2D Set > Page 4963 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Internal Transmission Wiring Harness - Removal Wiring Harness: Service and Repair Internal Transmission Wiring Harness - Removal REMOVAL 1. Raise and support the vehicle. 2. Place a suitable drain pan beneath the transmission oil pan (1). 3. Remove the bolts holding front and sides of the oil pan to the transmission. 4. Loosen the bolts holding the rear of the oil pan to transmission. 5. Slowly separate the front of pan away from transmission allowing the fluid to drain into the drain pan. 6. Hold up pan and remove remaining bolts holding the pan (1) to the transmission (4). 7. Support the oil pan and lower it from the transmission. 8. Pour any remaining fluid into the drain pan. 9. Separate the primary (2) and auxiliary (3) oil filters from valve body and oil pump and pour the fluid from the filters into the drain pan. 10. Inspect the oil filter seal in the bottom of the oil pump. If the seal is not installed completely in the oil pump, or is otherwise damaged, remove it with a suitable tool, and discard the oil filter seals from the bottom of the oil pump. The seals can be reused if they are in good condition. 11. Disconnect the TEHCM 2-way electrical jumper connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Internal Transmission Wiring Harness - Removal > Page 4966 12. Disconnect the TEHCM electrical connector (1) from the valve body (2). NOTE: To remove, gently pull on the passage sleeve after disengaging the locking tab. If stuck use an internal expanding collet to remove. 13. Lift up the passage sleeve locking tab (1). Remove the passage sleeve by gripping firmly on two ends and pulling away from the transmission. 14. Remove the valve body bolts (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Internal Transmission Wiring Harness - Removal > Page 4967 15. Remove the valve body (2) and case seals (1), from the transmission case (3). 16. Disconnect the electric motors electrical connectors (1) from the main transmission harness (2). 17. Disconnect the transmission range sensor electrical connector (1) from the valve body connector (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Internal Transmission Wiring Harness - Removal > Page 4968 18. While squeezing the locking tabs (1) on the electrical connector (2), push the internal wiring harness into the transmission case. 19. Remove the internal wiring harness (1) from the transmission case (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Internal Transmission Wiring Harness - Removal > Page 4969 Wiring Harness: Service and Repair Internal Transmission Wiring Harness - Installation INSTALLATION 1. Route and install the main transmission internal wiring harness (1) to the transmission case (2). 2. Push the electrical connector (2) until the locking tabs (1) lock it into place. 3. Connect the transmission range sensor electrical connector (1) to the valve body connector (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Internal Transmission Wiring Harness - Removal > Page 4970 4. Connect the electric motor electrical connectors (1) to the main transmission harness (2). 5. Install the case seals (1), then position the valve body (2) back into the transmission case (3). 6. Install the valve body bolts (1) and tighten the bolts to 11 Nm (8 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Internal Transmission Wiring Harness - Removal > Page 4971 7. Connect the TEHCM electrical connector (1) to the valve body (2). 8. Connect the TEHCM 2-way electrical jumper connector (1). NOTE: Orientate the alignment tab inside the passage sleeve with the slot in the electrical connector of the control solenoid valve assembly. Push the sleeve straight into the case bore and connector. Do not rotate the sleeve at any time. Make sure the sleeve is fully seated into the case. When the sleeve is properly installed, the distance from the case to the end of the sleeve should be 14-16 mm (0.55-0.63 in.). 9. Lubricate the seals on the passage sleeve with DEXRON(R) VI and install the passage sleeve by pushing it into the transmission case. 10. Push up on the passage sleeve locking tab (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Service and Repair > Internal Transmission Wiring Harness - Removal > Page 4972 CAUTION: The primary and auxiliary oil filter seals MUST be fully installed flush against the oil pump body. DO NOT install the seals onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result. 11. If necessary, install new primary and auxiliary oil filter seals in the oil pump inlet bore. Seat the seals in the bore with Installer 6960 or another suitable tool (appropriately sized drift or socket or the butt end of a hammer). 12. Install the auxiliary oil filter assembly (3). 13. Install the primary oil filter assembly (2). 14. Install the transmission oil pan and gasket (1). Install and tighten the transmission oil pan bolts to 27 Nm (20 ft. lbs.). 15. Lower vehicle and fill transmission with DEXRON(R) VI. . See: Service and Repair/Procedures/Transmission Fill Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Clutch Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4979 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Differential, CVT > Differential Fluid - CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4986 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - CVT: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Fluid CVT > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 4991 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Front Axle - C205F Differential Cover: Service and Repair Front Axle - C205F Removal REMOVAL 1. Remove fill plug. 2. Remove differential cover bolts. 3. Remove cover and drain fluid. Installation INSTALLATION 1. Apply a bead of orange Mopar(TM) Axle RTV Sealant (1) or equivalent to the housing cover (2). CAUTION: If cover is not installed within three to five minutes, the cover must be cleaned and new RTV applied. Failure to follow these instructions will compromise adhesion quality. 2. Install cover and tighten bolts in a criss-cross pattern to 22.5 Nm (16.5 ft. lbs.). 3. Fill differential with lubricant to specifications. 4. Install fill plug and tighten to 34 Nm (25 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > Front Axle - C205F > Page 4997 Differential Cover: Service and Repair Rear Axle - 9 1/4 Removal REMOVAL 1. Remove watts link bell crank bolt (2) from differential cover (1). 2. Remove differential cover bolts. 3. Remove cover and drain fluid. Installation INSTALLATION 1. Clean differential cover. 2. Apply a bead of orange Mopar(TM) Axle RTV Sealant (1) or equivalent to the cover (2). CAUTION: If cover is not installed within 3 to 5 minutes, the cover must be cleaned and new RTV applied or adhesion quality will be compromised. 3. Install cover and tighten bolts in a criss-cross pattern to 44 Nm (32 ft. lbs.). 4. Fill differential with lubricant to specifications. CAUTION: Fill differential by volume only, not to the bottom of fill plug. 5. Install fill hole plug. 6. Install watts link bell crank bolt and tighten to 217 Nm (160 ft. lbs.). NOTE: Bell crank bolt has a Loctite(R) patch, a new bolt should be used. If bolt is not available, clean bolt and apply Loctite(R) 242 to the threads. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Differential: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5002 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Axle C20F .................................................................................................................................................... .............................................................. 55 oz (1.6 L) Rear Axle 8 1/4 Hybred Electric Vehicle (HEV) .................................................................................................... ............................................................ 64 oz (1.9L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 5005 Fluid - Differential: Fluid Type Specifications Front Axle C20F .................................................................................................................................................... ................................. Mopar Gear Lubricant 75W-90 Rear Axle 8 1/4 Hybred Electric Vehicle (HEV) .......................................................................... SAE 75W-90 multipurpose type, GL-5 gear lubricant or equivalent Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F Seals and Gaskets: Service and Repair Front Axle - C205F Axle Shaft Seal - Removal REMOVAL 1. Remove half shaft and axle shaft. 2. Remove axle shaft seal with a small pry bar. Axle Shaft Seal - Installation INSTALLATION 1. Wipe axle shaft tube bore clean. 2. Install new axle shaft seal with Installer 8402 (1). 3. Install axle shaft and half shaft. Pinion Seal - Removal REMOVAL 1. Remove both half shafts. 2. Mark propeller shaft (2) and pinion flange (4) for installation reference. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 5010 3. Remove front propeller shaft. 4. Rotate pinion gear three to four times, to verify pinion rotates smoothly. 5. Record pinion torque to rotate flange (1) with an inch pound torque wrench (2) for installation reference. 6. Hold flange with Holder 6719A and four bolts and washers. 7. Remove pinion nut. 8. Mark a line across the pinion shaft and flange (1) for installation reference. 9. Remove flange (1) with Remover C-452 (2). 10. Remove pinion seal with seal puller. Pinion Seal - Installation INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 5011 1. Apply a light coating of gear lubricant on the lip of pinion seal. 2. Install seal with Installer 8695 (2) and Handle C-4171 (1) . 3. Position flange on pinion shaft with reference marks aligned. 4. Install pinion flange onto the pinion with Installer C-3718 and holder. 5. Hold pinion flange with Holder 6719A (2). 6. Install new pinion nut and tighten pinion nut to 271 Nm (200 ft. lbs.).NOTE: Do not exceed minimum tightening torque 271 Nm (200 ft. lbs.) when tighten pinion nut at this point. 7. Record pinion torque to rotate (1), with a torque wrench (2). Pinion torque to rotating should be equal to recorded reading plus an additional 0.56 Nm (5 in. lbs.). If pinion torque to rotating is low, tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotate is achieved. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 5012 CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque. If pinion torque to rotating or maximum tightening torque 474 Nm (350 ft. lbs.) is exceeded a new collapsible spacer must be installed. Failure to follow these instruction will result in damage to the axle. 8. Install propeller shaft with reference marks aligned. 9. Install half shafts. 10. Add gear lubricant to differential housing if necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 5013 Seals and Gaskets: Service and Repair Rear Axle - 9 1/4 Axle Shaft Seal - Removal REMOVAL 1. Remove axle shaft. 2. Remove axle shaft seal (1) from end of the axle tube (2) with a pry bar. Axle Shaft Seal - Installation INSTALLATION 1. Remove any old sealer/burrs from axle tube. 2. Coat new seal lip with axle lubricant and install seal with Installer 9337 (1) and Handle C-4171 (2). 3. Install axle shaft. Pinion Seal - Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 5014 1. With vehicle in neutral, position it on a hoist. 2. Mark a installation reference line (3) across the pinion flange (3) and propeller shaft flange (4). 3. Remove propeller shaft. 4. Remove brake calipers and rotors to prevent any drag. 5. Rotate pinion flange three or four times and verify flange rotates smoothly. 6. Record pinion torque to rotate (1) with a inch pound torque wrench (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 5015 7. Install two bolts into the pinion flange threaded holes, 180 degrees apart. Position Holder 6719A against the flange and install and tighten two bolts and washers into the remaining holes. 8. Hold the flange with Holder 6719A and remove pinion nut and washer. 9. Mark a line across the pinion shaft and flange (1) for installation reference. 10. Remove companion flange (1) with Puller C-452 (2). 11. Remove pinion seal with seal puller. Pinion Seal - Installation INSTALLATION 1. Apply a light coating of gear lubricant on the lip of pinion seal. 2. Install new pinion seal with Installer C-4076-B (3) and Handle C-4735 (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > Front Axle - C205F > Page 5016 3. Install companion flange on the end of the shaft with the reference marks aligned. 4. Install two bolts into the threaded holes in the companion flange, 180° apart. 5. Position Holder 6719A (2) against the companion flange and install a bolt and washer into one of the remaining threaded holes. Tighten the bolts so holder is held to the flange. 6. Install companion flange on pinion shaft with Installer C-3718 and Holder 6719A. 7. Install pinion washer and a new pinion nut. The convex side of the washer must face outward. 8. Hold companion flange with Holder 6719A (2) and tighten pinion nut with a torque wrench (3) to 285 Nm (210 ft. lbs.).NOTE: Do not exceed the minimum torque 285 Nm (210 ft. lbs.) when installing the pinion nut at this point. 9. Rotate pinion several times to ensure pinion bearings are seated. 10. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotate should be equal to recorded reading plus an additional 0.56 Nm (5 in. lbs.). If pinion torque to rotate is low, tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotating is achieved. CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque. If pinion torque to rotating is exceeded, a new collapsible spacer must be installed. Failure to follow these instructions will result in damage to the axle. 11. Install propeller shaft. 12. Install rear brake rotors components. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205F Axle Bearing: Service and Repair Front Axle - C205F Removal REMOVAL 1. Remove half shaft, axle shaft and seal. 2. Install axle shaft bearing Remover C-4660-A (3) in the bearing (1). Then tighten the nut (2) to spread the remover in the bearing. 3. Install bearing remove cup (1) bearing (2) and nut (3). Tighten nut to draw bearing out. 4. Inspect axle shaft tube bore for roughness and burrs. Installation INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205F > Page 5022 1. Wipe the axle shaft tube bore clean. 2. Install axle shaft bearing with Installer 5063 (1) and Handle C-4171 (2). 3. Install new axle shaft seal with Installer 8402 (1). 4. Install axle shaft and half shaft. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205F > Page 5023 Axle Bearing: Service and Repair Rear Axle - 9 1/4 Removal REMOVAL 1. Remove axle shaft. 2. Remove axle seal with pry bar. 3. Position bearing Receiver 9338 (1) on axle tube. 4. Insert bearing Remover 6310 with Foot 6310-9 (3) through receiver (2) and bearing (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Front Axle - C205F > Page 5024 5. Tighten nut (1) to pull bearing into the receiver (3). Installation INSTALLATION 1. Remove any old sealer/burrs from axle tube. 2. Install axle shaft bearing with Installer 9337 (1) and Handle C-4171 (2). Drive bearing in until tool contacts the axle tube. NOTE: Bearing is installed with the bearing part number against the installer. 3. Coat new axle seal lip with axle lubricant and install with Installer 9337 and Handle C-4171. 4. Install axle shaft. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205F Axle Shaft: Service and Repair Front Axle - C205F Removal REMOVAL 1. Remove half shaft from vehicle. 2. Clean axle seal area. 3. Remove snap ring and O-ring from the axle shaft. 4. Remove axle (1) with Remover 8420A (2) (3) (4) and Slide Hammer C-3752. Installation INSTALLATION 1. Lubricate bearing bore and seal lip with gear lubricant. 2. Install axle shaft and engage shaft into side gear. Push firmly on axle shaft to engage snap-ring. 3. Install O-ring (1) and snap-ring (2) on shaft (3). 4. Check the differential fluid level and add fluid if necessary. 5. Install half shaft. 6. Install skid plate, if necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205F > Page 5030 Axle Shaft: Service and Repair Rear Axle - 9 1/4 Removal REMOVAL 1. With vehicle in neutral, position it on a hoist. 2. Remove brake caliper adapter with caliper and remove rotor. 3. Remove wheel speed sensors. 4. Remove differential housing cover and drain lubricant. 5. Remove pinion mate shaft (1) lock screw (2). 6. Remove pinion mate shaft (1) from differential case (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205F > Page 5031 7. Push axle shaft (2) inward and remove axle shaft C-lock (1). 8. Remove axle shaft. Installation INSTALLATION 1. Lubricate bearing bore and seal lip with gear lubricant. 2. Insert axle shaft (1) through seal (2) and engage into side gear splines. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle - C205F > Page 5032 3. Insert C-lock (1) in end of axle shaft (2) then push axle shaft outward to seat C-lock in side gear (3). 4. Insert pinion mate shaft (1) into differential case (2) and pinions gears. 5. Align hole in mate shaft (1) with hole in differential case. Install lock screw (2) with Loctite(R) on the threads. Tighten lock screw to 25 Nm (220 in. lbs.). 6. Install differential cover and fill with gear lubricant. 7. Install brake rotor and caliper adapter with caliper. 8. Install wheel speed sensors. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Drive Shaft, Inner Joint - Removal Constant Velocity Joint: Service and Repair Drive Shaft, Inner Joint - Removal REMOVAL 1. Place shaft in vise with soft jaws and support C/V joint. 2. Remove clamps (2) (4) with a cut-off wheel or grinder. NOTE: Do not damage C/V housing or half shaft with cut-off wheel or grinder. 3. Remove housing (2) from the half shaft and slide boot (1) down shaft. 4. Remove housing bushing from the housing. 5. Remove tripod (2) snap ring (1). 6. Remove tripod and boot from the half shaft. 7. Clean and inspect C/V components for excessive wear and damage. Replace the tripod as a unit only if necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Drive Shaft, Inner Joint - Removal > Page 5037 Constant Velocity Joint: Service and Repair Drive Shaft, Inner Joint - Installation INSTALLATION 1. Slide new boot down the half shaft. 2. Install tripod (1) and tripod snap ring on the half shaft. 3. Pack grease supplied with the joint/boot into the housing and boot. 4. Coat tripod with supplied grease. 5. Install new bushing (1) onto the housing (2). 6. Insert tripod and shaft in the housing. 7. Position boot (2) on the joint in its original position. NOTE: Verify boot is not twisted and remove any excess air. 8. Secure both boot clamps with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until the jaws of the tool are closed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Drive Shaft, Inner Joint - Removal > Page 5038 Constant Velocity Joint: Service and Repair Drive Shaft, Outer Joint - Removal REMOVAL 1. Place shaft in vise with soft jaws and support C/V joint. CAUTION: Do not damage C/V housing or half shaft. 2. Remove clamps (2) (4) with a cut-off wheel or grinder. 3. Slide the boot down the shaft. 4. Remove lubricant to expose the C/V joint snap ring. 5. Spread snap ring (1) and slide the joint off the shaft. 6. Slide boot off the shaft and discard old boot. 7. Mark alignment marks (1) on the inner race/hub (2), bearing cage (3) and housing with dabs of paint. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Drive Shaft, Inner Joint - Removal > Page 5039 8. Clamp C/V joint in a vertical position in a soft jawed vise. 9. Press down one side of the bearing cage (3) to gain access to the ball at the opposite side. NOTE: If joint is tight, use a hammer and brass drift to loosen the bearing hub. Do not contact the bearing cage with the drift. 10. Remove ball (4) from the bearing cage (3). 11. Repeat step above until all six balls are removed from the bearing cage. 12. Lift cage and inner race (2) upward and out from the housing (1). 13. Turn inner race 90° in the cage and rotate the inner race/hub out of the cage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Drive Shaft, Inner Joint - Removal > Page 5040 Constant Velocity Joint: Service and Repair Drive Shaft, Outer Joint - Installation INSTALLATION 1. Apply a light coat of grease to the C/V joint components before assembling them. 2. Align inner race, cage and housing according to the alignment reference marks. 3. Insert inner race (1) into the cage (2) and rotate race into the cage. 4. Rotate inner race/hub in the cage (1). 5. Insert cage into the housing (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Drive Shaft, Inner Joint - Removal > Page 5041 6. Rotate cage 90° into the housing (1). 7. Apply lubricant included with replacement boot/joint to the ball races. Spread lubricant equally between all the races. 8. Tilt inner race/hub (2) and cage (3) and install the balls (4). 9. Place new clamps onto new boot and slide boot onto the shaft to its original position. 10. Apply the rest of lubricant to the C/V joint and boot. 11. Push the joint onto the shaft until the snap ring (1) seats in the groove (3). Pull on the joint to verify the span ring has engaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Drive Shaft, Inner Joint - Removal > Page 5042 12. Position boot on the joint in its original position. Ensure boot is not twisted and remove any excess air. 13. Secure both boot clamps (2) (4) with Clamp Installer C-4975A. Place tool on clamp bridge and tighten tool until the jaws of the tool are closed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Mopar Multi-Purpose Lube NLGI Grade 2 EP, GC-LB Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal Wheel Bearing: Service and Repair Front Hub and Bearing - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 4. Remove the ABS wheel speed sensor if equipped, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor - Removal/Front. 5. Remove the halfshaft nut 4X4 only. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod (2) from the knuckle using puller 8677 (1). 7. Remove the upper ball joint nut and separate the upper ball joint (1) from the knuckle (3) using puller 8677 (2). 8. Pull down on the steering knuckle to separate the half shaft from the hub/bearing. 4X4 only Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5048 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 5049 Wheel Bearing: Service and Repair Front Hub and Bearing - Installation INSTALLATION 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. 4. Install the ABS wheel speed sensor (4) if equipped See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor - Installation/Front. 5. Install the upper ball joint nut to the steering knuckle and tighten to 75 Nm (55 ft. lbs.). 6. Install the tie rod end nut to the steering knuckle and tighten to 75 Nm (55 ft. lbs.). 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.) 4X4 only. 8. Install the wheel and tire assembly See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. 9. Remove the support and lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications AXLE NUT Half Shaft Nut....................................................................................................................................... ...................................................251 Nm (185 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications Drive/Propeller Shaft: Specifications TORQUE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 5058 Drive/Propeller Shaft: Testing and Inspection PROPELLER SHAFT PROPELLER SHAFT VIBRATION Out-of-round tires or wheels that are out of balance, will cause a low frequency vibration. Driveline vibration can also be caused by loose or damaged engine mounts. Propeller shaft vibration increases with vehicle speed. A vibration that occurs at a specific speed range, is not usually caused by an out of balance propeller shaft. Defective universal joints or an incorrect propeller shaft angle are usually the cause of such a vibration. DRIVELINE VIBRATION PROPELLER SHAFT BALANCE If propeller shaft is suspected of being out of balance, use the following procedure. NOTE: Indexing propeller shaft 180 degrees relative to the yoke may eliminate some vibrations. 1. Raise and support vehicle. 2. Clean all foreign material from the propeller shaft and universal joints. 3. Inspect propeller shaft for missing balance weights, broken welds and bent areas. If propeller shaft is bent, it must be replaced. 4. Inspect universal joints for wear and properly installed. 5. Check propeller shaft bolt torques. 6. Remove wheels and install lug nuts to retain brake rotors. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Specifications > Page 5059 7. Mark and number the shaft six inches from the pinion yoke end at four positions 90 degrees apart. 8. Run and accelerate vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine. 9. Install a screw clamp at position (1). 10. Start engine and check vibration. If there is little or no change move the clamp to the next positions. Repeat the vibration test. NOTE: If there is no difference in vibration at this positions, the vibration may not be the propeller shaft. 11. If vibration decreased, install a second clamp (1) and repeat the test. 12. If additional clamp causes an additional vibration, separate the clamps 1/2 inch (1) above and below the mark. Repeat the vibration test. 13. Increase distance between the clamp screws (1) (2) and repeat test, until the least amount of vibration is noticed. Bend the slack end of the clamps so screws will not loosen. 14. If vibration remains unacceptable, repeat the procedure to the front end of the propeller shaft. 15. Install wheels and lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures Drive/Propeller Shaft: Procedures PROPELLER SHAFT ANGLE NOTE: This procedure applies to the front and rear propeller shaft. 1. Raise and support vehicle at the axles as level as possible, allowing wheels and propeller shaft to turn. 2. Remove universal joint snap rings if equipped, so inclinometer base will sit flat. 3. Rotate shaft until transmission/transfer case output yoke bearing cap is facing downward. NOTE: Always make measurements from front to rear and from the same side of the vehicle. 4. Place Inclinometer 7663 on yoke bearing cap or pinion flange ring, parallel to the shaft. Center bubble in sight glass and record measurement (A). This measurement will give you the transmission or Output Yoke Angle (A). 5. Rotate propeller shaft 90 degrees and place Inclinometer 7663 on yoke bearing cap parallel to the shaft. Center bubble in sight glass and record measurement (C). This measurement can also be taken at the rear end of the shaft. This measurement will give you the propeller shaft angle (C). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 5062 6. Subtract smaller figure from larger (C minus A) to obtain transmission output operating angle. 7. Rotate propeller shaft 90 degrees and place Inclinometer 7663 on pinion yoke bearing cap parallel to the shaft. Center bubble in sight glass and record measurement (B). This measurement will give you the pinion shaft or input yoke angle (B). 8. Subtract smaller figure from larger (C minus B) to obtain axle Input Operating Angle. PROPELLER SHAFT ANGLE RULES - Good cancellation of U-joint operating angles is within 1 degree. - Operating angles less than 3 degrees. - At least 1/2 of one degree continuous operating (propeller shaft) angle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 5063 Drive/Propeller Shaft: Removal and Replacement Front REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Remove skid plate if equipped. 3. Mark a reference line (3) across propeller shaft flange and pinion flange (2). 4. Remove exhaust crossover bolts from exhaust manifolds and lower crossover. 5. Remove boot clamp (3) from CV joint (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 5064 6. Remove propeller shaft (1) flange bolts (2). 7. Slide propeller shaft off the transfer case and remove shaft. CAUTION: Failure to follow these instructions may result in a driveline vibration. Rear REMOVAL 1. With vehicle in neutral, position vehicle on hoist. 2. Mark a reference line (3) across the pinion flange (2) and propeller shaft (1) flange (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 5065 3. Remove pinion flange (1) bolts from propeller shaft flange (2). 4. Slide propeller shaft back off automatic transmission/transfer case output shaft, then mark propeller shaft (1) and transmission/transfer case output shaft (2) for installation reference. 5. Remove propeller shaft from vehicle. CAUTION: Failure to follow these instructions may result in a driveline vibration. Front INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 5066 1. Slide propeller shaft (1) onto transfer case (4). 2. Install CV boot clamp (3). 3. Align propeller shaft (1) and pinion flange (2) reference marks (3). 4. Install new propeller shaft flange bolts (2) and tighten to 115 Nm (85 ft. lbs.). NOTE: Flange bolts incorporate a Loctite(R) patch, new bolts should be used. If bolts are not available, clean bolts and apply Mopar(R) Lock & Seal Adhesive or equivalent to the threads. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Procedures > Page 5067 CAUTION: Failure to follow these instruction may result in a driveline vibration. 5. Install skid plate, if equipped. Rear INSTALLATION 1. Slide slip yoke (1) onto automatic transmission/transfer case output shaft (2) with reference marks aligned. 2. Align reference marks on propeller shaft flange (2) and pinion flange (1). Install new companion flange (1) bolts and tighten to 115 Nm (85 ft. lbs.) NOTE: Flange bolts incorporate a Loctite(R) patch, new bolts should be used. If bolts are not available, clean bolts and apply Mopar(R) Lock & Seal Adhesive or equivalent to the threads. CAUTION: Failure to follow these instruction may result in a driveline vibration. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > Page 5068 Drive/Propeller Shaft: Tools and Equipment SPECIAL TOOLS INCLINOMETER 7663 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly Universal Joint: Service and Repair Disassembly With Injected Rings WITH INJECTED RINGS 1. Place shaft yoke in vise. 2. Position U-joint press (1) with receiver (2) on propeller shaft yoke. 3. Pressed U-joint bearing caps (1) out of shaft yoke (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly > Page 5073 4. Remove lower bearing cap from shaft yoke. 5. Turn shaft over and position press (1) with receiver (2) on shaft yoke. 6. Press remaining U-joint bearing cap out of shaft yoke. 7. Remove flange (1) with U-joint out of shaft yoke (2). 8. Position U-joint press (2) with receiver (1) on flange. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly > Page 5074 9. Press U-joint bearing caps (1) out of flange (2). 10. Remove bearing cap on the outside of the flange. 11. Position U-joint press (2) with receiver (1) on flange. 12. Press remaining U-joint bearing cap out of flange. 13. Remove U-joint from flange. With Snap Rings WITH SNAP RINGS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly > Page 5075 NOTE: This procedure describes a propeller shaft equipped with a cardan joint in the tube yoke. For propeller shafts equipped with a companion/slip yoke, repeat the steps to remove the remaining cardan joint. 1. Tap outside of bearing cap with a drift to loosen snap ring. 2. Remove snap rings (1) from both sides of yoke. 3. Position yoke with the grease fitting if equipped, pointing up. 4. Position a socket with a inside diameter large enough to receive the bearing cap, beneath the yoke on a press. 5. Place another socket with an outside diameter smaller than bearing cap on the upper bearing cap and press (1) the lower cap through the yoke. NOTE: If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the bearing cap to dislodge the cap. 6. Pull bearing cap of the yoke. 7. Turn yoke over in the press and straighten the cross (1). Press the cross until the remaining bearing cap (2) can be removed. CAUTION: If cross or bearing cap are not straight during removal, the bearing cap will score the walls of the yoke bore and damage can occur. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly > Page 5076 Universal Joint: Service and Repair Assembly With Injected Rings WITH INJECTED RINGS NOTE: Replacement joint has internal snap rings. 1. Place joint in flange with one bearing cap. 2. Position press (3) with receiver (1) on flange and bearing cap (2). 3. Press bearing cap until snap ring groove (1) is through the flange (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly > Page 5077 4. Install snap ring (2) on bearing (1). 5. Position press (3) with receiver (2) on remaining bearing cap (1) and flange. 6. Press bearing cap until snap ring groove is through the flange. 7. Install snap ring (1) on bearing cap (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly > Page 5078 8. Install flange (1) with U-joint in yoke (2). 9. Position press (2) with receiver (1) and lower bearing cap (3) on yoke. 10. Press bearing cap until snap ring groove is through the yoke. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly > Page 5079 11. Install snap ring (2) on bearing cap (1). 12. Position press (2) with receiver (3) on remaining bearing cap (1) and yoke. 13. Press remaining bearing cap until snap ring groove is through the yoke. 14. Install snap ring (2) on bearing cap (1). With Snap Rings WITH SNAP RINGS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly > Page 5080 NOTE: This procedure describes a propeller shaft equipped a cardan joint in the tube yoke. For propeller shafts equipped with a companion/slip yoke, repeat the steps to remove the remaining cardan joint. 1. Apply (EP) N.L.G.I. Grade 1 or 2 grease to inside of yoke bores. 2. Position cross (1) in yoke with lube fitting pointing up, if equipped. 3. Place a bearing cap (1) over the cross end (2) and align cap with yoke bore. 4. Press bearing cap into the yoke bore enough to clear snap ring groove. 5. Repeat 3 and 4 to install the opposite bearing cap. NOTE: If joint is stiff or binding, strike the yoke with a soft hammer to seat the needle bearings. 6. Add grease to lube fitting, if equipped. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications FLEXPLATE Flexplate-to-crankshaft bolts................................................................................................................ .......................................................95 Nm (70 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Flexplate - Removal Flex Plate: Service and Repair Flexplate - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Power the vehicle down . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Down 2. Remove the transmission See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement/Removal. 3. Remove the flex plate bolts. 4. Remove the flex plate. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Service and Repair > Flexplate - Removal > Page 5086 Flex Plate: Service and Repair Flexplate - Installation INSTALLATION WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Position the flexplate onto the crankshaft and install the bolts hand tight. 2. Tighten the flexplate retaining bolts to 95 Nm (70 ft. lbs.). 3. Install the transmission See: Automatic Transmission/Transaxle/Service and Repair/Removal and Replacement/Removal. 4. Power up the vehicle . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair/Battery System - High Voltage Power Up 5. Start engine and check for leaks. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Tow/Haul Indicator - Description Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator - Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. The tow/haul indicator is located below the minor gauge set on the left side of the cluster. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Tow/Haul Indicator - Description > Page 5093 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator - Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-on message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - self Test - Each time the cluster is put through the self test, the tow/haul indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transmission control system, the PCM, the CCN, the CAN data bus or the electronic communication related to tow/haul indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description Four Wheel Drive Indicator Lamp: Description and Operation 4WD Indicator - Description 4WD INDICATOR A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD indicator is located below the minor gauge set on the left side of the cluster. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 5099 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Low Indicator - Description 4WD LOW INDICATOR A 4WD low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD low indicator is located below the minor gauge set on the left side of the cluster. The 4WD low indicator consists of a stencil-like cutout of the text 4LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD low indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 5100 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Indicator - Operation 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-on message from the FCM, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the 4WD indicator will be turned ON, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD mode is engaged. The FCM then sends the proper lamp-on or lamp-off message to the instrument cluster also known as the Cab Compartment Node (CCN). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transfer case shift motor/mode sensor, the FCM, the CCN, the CAN data bus or the electronic communication related to 4WD indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 5101 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Low Indicator - Operation 4WD LOW INDICATOR The 4WD low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The 4WD low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the 4WD low indicator for the following reasons: - 4WD Low Indicator Lamp-On Message- Each time the cluster receives an electronic 4WD low indicator lamp-on message from the FCM, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the 4WD low indicator turns on, then off again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The FCM then sends the proper lamp-on or lamp-off message to the Instrument Cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the 4WD low indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transfer case shift motor/mode sensor, the FCM, the CCN, the CAN data bus or the electronic communication related to 4WD low indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Service 4WD Indicator - Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Service 4WD Indicator Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located below the minor gauge set on the left side of the cluster. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Service 4WD Indicator - Description > Page 5106 Malfunction Indicator Lamp - Transfer Case: Description and Operation Service 4WD Indicator Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Front Control Module (FCM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the FCM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-on message from the FCM, the service 4WD indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-off messages from the FCM for 10 seconds, the service 4WD indicator is illuminated by the cluster to indicate a loss of FCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the FCM. - Self Test - Each time the cluster is put through the self test, the service 4WD indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The FCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the FCM, the CCN, the CAN data bus or the electronic communication related to service 4WD indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Differential, Manual Transaxle > Differential Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5113 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - M/T: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5118 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description Control Module: Description and Operation Transmission Control Module - Description DESCRIPTION RFE - RLE TRANSMISSIONS The Transmission Control Module (TCM) is a sub-module within the Powertrain Control Module (PCM). The PCM is located on the right inner fender. EVT AHS-T TRANSMISSION TEHCM MOUNTING BOLTS On vehicles equipped with the AHS-T HEV transmission the TCM is imbedded into the Transmission Electronic Hydraulic Control Module (TECHM) that is mounted to the valve body and is not serviceable, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 5125 Control Module: Description and Operation Transmission Control Module - Operation OPERATION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning/TCM Quick Learn BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 5126 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: 42RLE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 5127 545RFE EVT AHS-T SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 5128 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures Control Module: Procedures STANDARD PROCEDURE - RESOLVER LEARN RESOLVER OFFSET LEARN TRIGGER EVT AHS-T TRANSMISSION The Resolver Offset Learn Trigger Procedure requires the use of a scan tool. This program allows the electronic variable transmission (EVT) AHS-T to re-calibrate itself. This will provide the proper transmission operation. The resolver offset learn procedure should be performed if any of the following procedures are performed: - Transmission Assembly Replacement - Transmission Electronic Hydraulic Control Module (TEHCM) Replacement - Flashing the TCM - Electric Motors Replacement - Valve Body Replacement or Recondition To perform the Resolver Offset Learn Trigger Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The shift lever position must stay in PARK until prompted to shift. - The calculated oil temperature must be above 15° C (60° F) and below 93° C (200° F) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 5131 Control Module: Removal and Replacement Transmission Control Module - Removal REMOVAL WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. NOTE: If the TECHM is being flashed, removed or replaced, it is necessary to perform the Resolver Offset Learn Trigger procedure using the scan tool. 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove the drain plug, if equipped. 4. Remove the auxiliary oil pump mounting bolts (1). 5. Remove the auxiliary oil pump (2). 6. Remove the transmission oil pan (1), the primary oil filter (2) and the auxiliary oil filter (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 5132 7. Lift up the passage sleeve locking tab (1). Remove the passage sleeve by gripping firmly on two ends and pulling the sleeve away. 8. Disconnect the TEHCM 2-way electrical jumper connector (1) from the internal transmission harness. 9. Disconnect the TEHCM electrical connector (1) from the valve body (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 5133 10. Remove the TEHCM side mounting bolts (1) and main mounting bolts (2) from the valve body. 11. Disconnect the TEHCM jumper harness. 12. If necessary remove the TECHM filter screen (1). Transmission Control Module - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 5134 INSTALLATION WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. NOTE: If the TECHM is being flashed, removed or replaced, it is necessary to perform the Resolver Offset Learn Trigger procedure using the scan tool. 1. Install the filter screen onto the TEHCM. TEHCM JUMPER CONNECTOR 2. Connect the TEHCM jumper harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 5135 TEHCM MOUNTING BOLTS 3. Install the TECHM heat sink bolts (1). Tighten the bolts to 7 Nm (62 in.lbs.). 4. Install the TECHM mounting bolts (2). Tighten the bolts to 11 Nm (97 in.lbs.). 5. Connect the 2-way TEHCM electrical connector (1). 6. Connect the TEHCM electrical connector (1) to the valve body. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 5136 NOTE: Orientate the alignment tab inside the passage sleeve with the slot in the electrical connector of the control solenoid valve assembly. Push the sleeve straight into the case bore and connector. Do NOT rotate the sleeve at any time. Ensure the sleeve is fully seated into the case. When the sleeve is properly installed, the distance from the case surface to the end of the sleeve should be 14-16 mm. 7. Lubricate the seals on the passage sleeve with DEXRON(R) VI. Install the passage sleeve (2). Push down on the passage locking tab (1) to secure. NOTE: Using a suitable solvent, clean the oil pan and magnet. 8. Install the auxiliary oil filter assembly (3). 9. Install the primary oil filter assembly (2). 10. Install the oil pan gasket and the oil pan (1) onto the transmission case. Install the oil pan bolts. Tighten the oil pan bolts to 27 Nm (19 ft.lbs.). 11. Install the auxiliary oil pump (2) with a NEW gasket. 12. Install the auxiliary oil pump bolts (1). Tighten the bolts to 11 Nm (97 in.lbs.). 13. Check and fill the transmission as necessary with DEXRON(R) VI transmission fluid. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5140 Transmission Control System Relay: Diagrams Connector (IN PDC) RELAY-TRANSMISSION CONTROL (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way Control Module: Diagrams Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way Connector C1 (HEV) - (HEADLAMP AND DASH) 16 WAY MODULE-FINAL DRIVE CONTROL (HEV) - (HEADLAMP AND DASH) 16 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way > Page 5146 Control Module: Diagrams Final Drive Control Module C2 (HEV) (Headlamp And Dash) 4 Way Connector C2 (HEV) - (HEADLAMP AND DASH) 4 WAY MODULE-FINAL DRIVE CONTROL (HEV) - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description Control Module: Description and Operation Final Drive Control Module - Description DESCRIPTION FDCM (Final Drive Control Module) is an electronic module that controls the shifting of the AWD new "Active on Demand" MP3010 single speed transfer case. This plastic cased module is packaged in the (Pedal Assembly) MAG bracket for the HB/HG HEV vehicle. Communication is via the CAN serial bus. The FDCM is installed inside the passenger compartment behind the driver side knee bolster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 5149 Control Module: Description and Operation Final Drive Control Module - Operation OPERATION POWER UP/DOWN The Final Drive Control Module (FDCM) will power up with an OFF/ON transition of the hard wired ignition switch input, or with the presence of active CAN C communications. The FDCM will power down when the vehicle ignition switch transitions from ON to OFF, or there are no CAN C messages, or there are no system requirements that dictate the controller to remain active START-UP DIAGNOSTICS When the FDCM is activated, the internal circuitry will undergo a diagnostic procedure. The controller will examine all inputs and outputs for short circuits to ground, short circuits to battery and open circuits and will also verify proper CPU and memory operation. If a fault is detected, a message will be sent out over the CAN C bus to the Cluster based Electronic Vehicle Information Center (EVIC) indicating that service is recommended. After passing all diagnostic tests, the controller will receive and process inputs and produce the appropriate outputs. Proper monitoring of the controller inputs and outputs performance will continue. INPUTS/OUTPUTS The following are inputs to the FDCM: - Lateral Accelerometer - Transfer Case Mode Sensor Signal - 3 Direct Battery Feeds - Ignition RUN Sense - Sensor Grounds - Module Grounds - CAN C Bus The following are outputs of the FDCM: - 5V Sensor Supply - Transfer Case Bi-directional Motor Control (A AND B) TRANSFER CASE MODE SENSOR SIGNAL The Transfer Case Mode Sensor Signal Input will provide the FDCM feedback about the position of the transfer case. The mode sensor will be a linear analog position sensor with a 1.4K +/- 20% potentiometer and a 1 K +/- 20% resistor that converts the motor shaft position into a multiplexed voltage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 5150 SLIP CONTROL Slip Control increases torque to the front axle when a relative slip is detected between the front and the rear prop shafts. Slip Control adjusts according to the vehicle speed and allows a permissible slip. Utilizes a closed loop strategy for permissible slip and speed of engagement. STABILITY CONTROL Stability control modifies the torque request based upon the vehicle dynamics under the over-steer and under-steer conditions. It monitors the yaw rate and the lateral acceleration to modify the clutch capacity to bring the vehicle back to a more neutral attitude. Compensates for high load conditions by monitoring the vehicle acceleration and changing the torque capacity. REGENERATIVE BRAKING STRATEGY During the event of regenerative braking the software splits the torque indicated by the signal axle in a ratio of 47:53 front and rear respectively. This torque split is to be modified to achieve optimum efficiency levels during a braking event. MODES OF OPERATION Normal Operation This mode is achieved by the ignition being switched in the RUN position, which powers up the 5V regulator and generates the appropriate RESET for the microprocessor. This mode also includes any required power-up system checks. Shut Down Mode This mode is activated when the ignition switch turned to the off position. The FDCM will perform any required Shut Down tasks prior to turning off the 5V regulator. Limp-In Mode This mode is entered when the FDCM has detected an error condition that prevents the system from performing its' required task. The FDCM operation will vary depending from modified operation to total system shut down based on the failure that has occurred. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal Control Module: Service and Repair Final Drive Control Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect the module electrical connectors. 3. Using a trim stick C-4755 or equivalent, gently pry back on the retaining tabs on the mounting plate and remove module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal > Page 5153 Control Module: Service and Repair Final Drive Control Module - Installation INSTALLATION 1. Place the final drive control module in its location on the mounting plate and firmly snap into place. 2. Connect the electrical connectors. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 5159 Fluid Pressure Sensor/Switch: Diagrams Connector (4.7L/5.7L) - (ENGINE) 4 WAY SENSOR-LINE PRESSURE (4.7L/5.7L) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 5163 Overdrive Switch: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SWITCH-TOW/HAUL OVERDRIVE - (INSTRUMENT PANEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Overdrive Lockout Switch - Description Overdrive Switch: Description and Operation Overdrive Lockout Switch - Description DESCRIPTION The tow/haul on control switch is located in the shift lever arm. The switch is a momentary contact device that signals the Powertrain Control Module (PCM) to toggle current status of the overdrive function. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Overdrive Lockout Switch - Description > Page 5166 Overdrive Switch: Description and Operation Overdrive Lockout Switch - Operation OPERATION Tow/haul is only used in the D position. When used while towing, the electronic control module (ECU) commands hybrid system to create more positive axle torque to the wheels. When used while coasting downhill and the vehicle gains speed, the ECU commands the hybrid system to create more negative axle torque to the wheels, helping the vehicle to maintain the correct speed. The Powertrain Control Module (PCM) stores a target speed when the accelerator and brake are released, if vehicle speed increases due to a hill, then additional negative wheel torque is added to the PCMs wheel torque request. The Hybrid Control Processor (HCP) follows the PCMs command and downshifts as required to meet the negative torque request. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Overdrive Lockout Switch Removal Overdrive Switch: Service and Repair Overdrive Lockout Switch - Removal REMOVAL 1. Using a plastic trim tool (3), remove the tow/haul switch retainer (2) from the gearshift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Overdrive Lockout Switch Removal > Page 5169 Overdrive Switch: Service and Repair Overdrive Lockout Switch - Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul switch (3) into the connector (2). 3. Push the tow/haul switch (3) and wiring into the shift lever (1). 4. Install the tow/haul switch retainer onto the shift lever. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5173 Transmission Position Switch/Sensor: Diagrams Connector (HEV) - (TRANSMISSION SIDE) 12 WAY SENSOR-TRANSMISSION RANGE (HEV) - (TRANSMISSION SIDE) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Description DESCRIPTION The transmission range sensor (2) is located inside the transmission and connects to the mainshaft (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description > Page 5176 Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body. See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body Removal. 2. Disconnect the transmission range sensor electrical connector (1). 3. Remove the bolt (1) securing the transmission range sensor (2) to the mainshaft (3). 4. Remove the mainshaft roll pin (1) from the transmission case (2) and remove the mainshaft. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 5179 5. Lower the transmission range sensor (2) and remove the park actuator rod (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 5180 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install the park actuator rod (3) into the transmission range sensor (2). 2. Install the mainshaft roll pin (1) to the transmission case (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 5181 3. Position the transmission range sensor (2) into place in the transmission case. 4. Install the mainshaft (3) into the transmission case. 5. Install the transmission range sensor mounting bolt. Tighten the bolt to 8 Nm (71 NOTE: Before install the TEHCM / valve body assembly to the transmission case, be certain the existing gasket is in place. 6. Install the valve body. See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 5186 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 5187 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way Transmission Speed Sensor: Diagrams Input Speed Sensor (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-INPUT SPEED - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way > Page 5190 Transmission Speed Sensor: Diagrams Output Speed Sensor (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-OUTPUT SPEED - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way > Page 5191 Transmission Speed Sensor: Diagrams Output Speed Sensor (HEV) Engine 2 Way Connector (HEV) - ENGINE 2 WAY SENSOR-OUTPUT SPEED (HEV) - ENGINE 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Oil Temperature Sensor - Description Transmission Temperature Sensor/Switch: Description and Operation Transmission Oil Temperature Sensor - Description DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Electronic Hydraulic Control Module (TEHCM). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Oil Temperature Sensor - Description > Page 5196 Transmission Temperature Sensor/Switch: Description and Operation Transmission Oil Temperature Sensor - Operation OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature. - Engine coolant temperature. - In-gear run time since start-up. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5201 Four Wheel Drive Selector Switch: Diagrams Connector - (INSTRUMENT PANEL) 10 WAY SWITCH-TRANSFER CASE SELECTOR - (INSTRUMENT PANEL) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 5205 Gear Sensor/Switch: Diagrams Connector - (ENGINE) 8 WAY ASSEMBLY-SHIFT MOTOR/MODE SENSOR - (ENGINE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > Mode Sensor - Description Gear Sensor/Switch: Description and Operation Mode Sensor - Description DESCRIPTION The transfer case encoder (3) provides the Drive Train Control Module (DTCM) feedback about the position of the transfer case. The sensor consists of a linear analog position sensor that converts the motor output shaft position into a DC signal. The sensor may rotate a full 360 degrees. When the DTCM is not in sleep mode, it must supply 5 VDC (+/- 0.5 v) to the sensor and monitor the shift motor position. The sensor position is monitored when the ignition is in the RUN position and for 10 seconds after the ignition is turned to the OFF position. The sensor is mechanically linked to the shaft of the cam allowing the transfer case to shift. The mode sensor draws less than 20 mA of current during operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > Mode Sensor - Description > Page 5208 Gear Sensor/Switch: Description and Operation Mode Sensor - Operation OPERATION During normal vehicle operation, the DTCM monitors the mode sensor outputs at least every 2 milliseconds when the shift motor is stationary or active. The mode sensor position will be considered invalid by the DTCM if the voltage is greater than 4.75 V or if it is less than 0.25 V. NOTE: All the parameter voltages referred to in the following information are calibrated items in the controller software and are subject to change. The DTCM shall consider Transfer Case position based on the MODE SENSOR VOLTAGES table listed below: MODE SENSOR VOLTAGES Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Mode Sensor - Removal Gear Sensor/Switch: Service and Repair Mode Sensor - Removal REMOVAL 1. Remove the wiring harness electrical connector from the encoder. 2. Remove the screws securing the encoder to the rear transfer case housing. 3. Remove the encoder (1) from the transfer case (2). 4. Remove the O-ring seal (1) from the encoder (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Mode Sensor - Removal > Page 5211 Gear Sensor/Switch: Service and Repair Mode Sensor - Installation INSTALLATION 1. Install a NEW O-ring seal (1) onto the encoder (2). NOTE: Before installing the encoder onto the transfer case, be certain to align the encoder shaft to the shift shaft and the dowel on the encoder to the hole in the case accordingly. 2. Install the encoder (1) onto the rear transfer case housing (2). 3. Install the encoder screws. Tighten the screws to 7 Nm (62 in.lbs.). 4. Install the electrical wiring harness connector onto the encoder. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Transfer Case Encoder Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Transfer Case Encoder > Page 5218 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Transfer Case Encoder > Page 5219 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Shift Motor/Mode Sensor Assembly (Engine) 8 Way Transfer Case Actuator: Diagrams Shift Motor/Mode Sensor Assembly (Engine) 8 Way Connector - (ENGINE) 8 WAY ASSEMBLY-SHIFT MOTOR/MODE SENSOR - (ENGINE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Shift Motor/Mode Sensor Assembly (Engine) 8 Way > Page 5222 Transfer Case Actuator: Diagrams Transfer Case Encoder (HEV) (Engine) 3 Way Connector (HEV) - (ENGINE) 3 WAY ENCODER-TRANSFER CASE (HEV) - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Shift Motor/Mode Sensor Assembly (Engine) 8 Way > Page 5223 Transfer Case Actuator: Diagrams Transfer Case Motor (HEV) Engine 4 Way Connector (HEV) - ENGINE 4 WAY MOTOR-TRANSFER CASE (HEV) - ENGINE 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > Shift Motor - Description Transfer Case Actuator: Description and Operation Shift Motor - Description DESCRIPTION The overall function of the shift motor (1) is an electromechanical device consisting of a DC permanent magnet motor and a position holding brake. The shift motors function is to move and lock a gear that moves the range fork and clutch lever found in the transfer case. This allows the transfer case to be shifted electrically to multiple operating positions (4WD AUTO, 4WD LOW and 2WD). The operating current of the shift motor under stall conditions is 30 amps maximum, at 22° C (72° F) with 13.5 volts, at the motor leads. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > Shift Motor - Description > Page 5226 Transfer Case Actuator: Description and Operation Shift Motor - Operation OPERATION Shifting in the transfer case occurs when a Pulse Width Modulated (PWM) voltage is supplied to the shift motor (1) by the Final Drive Control Module (FDCM). A linear analog position sensor (encoder) (3) located on the rear transfer case housing and provides the FDCM with the motor's angular, rotational position. With this information, the FDCM continuously knows the position of the motor, and therefore allows it to accurately control the operation of the motor, including voltage polarity which is used to control motor direction. The electronically controlled wet clutch pack uses an electric motor to actuate an internal gear train, clutch cam, and low range barrel cam. The clutch cam actuates the clutch levers that apply normal force to the multi-disc wet clutch pack. The clutch discs are alternately splined to the front and rear outputs. When normal force is applied to this clutch pack, torque is transferred to equalize speed differences between the front and rear axles. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Shift Motor - Removal Transfer Case Actuator: Service and Repair Shift Motor - Removal REMOVAL NOTE: New shift motor assemblies are shipped in the NEUTRAL position. If a new shift motor assembly must be installed, it will be necessary to shift the transfer case to the NEUTRAL position prior to motor installation. 1. Disconnect the electrical connector from the shift motor. 2. Remove the bolts holding the shift motor to the transfer case. 3. Remove the shift motor (1) from the transfer case. 4. Remove the O-ring seal (2) from the shift motor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Shift Motor - Removal > Page 5229 Transfer Case Actuator: Service and Repair Shift Motor - Installation INSTALLATION NOTE: Before installing the shift motor onto the transfer case, make certain that the shift motor shaft aligns with the transfer case worm shaft accordingly. 1. Install a NEW shift motor o-ring seal (2) onto the shift motor (1). 2. Install the shift motor (1) onto the transfer case. 3. Install the shift motor bolts. Tighten the shift motor bolts to 13 Nm (9 ft. lbs.). 4. Install the electrical wiring harness connector onto the shift motor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way Control Module: Diagrams Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way Connector C1 (HEV) - (HEADLAMP AND DASH) 16 WAY MODULE-FINAL DRIVE CONTROL (HEV) - (HEADLAMP AND DASH) 16 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way > Page 5234 Control Module: Diagrams Final Drive Control Module C2 (HEV) (Headlamp And Dash) 4 Way Connector C2 (HEV) - (HEADLAMP AND DASH) 4 WAY MODULE-FINAL DRIVE CONTROL (HEV) - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description Control Module: Description and Operation Final Drive Control Module - Description DESCRIPTION FDCM (Final Drive Control Module) is an electronic module that controls the shifting of the AWD new "Active on Demand" MP3010 single speed transfer case. This plastic cased module is packaged in the (Pedal Assembly) MAG bracket for the HB/HG HEV vehicle. Communication is via the CAN serial bus. The FDCM is installed inside the passenger compartment behind the driver side knee bolster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 5237 Control Module: Description and Operation Final Drive Control Module - Operation OPERATION POWER UP/DOWN The Final Drive Control Module (FDCM) will power up with an OFF/ON transition of the hard wired ignition switch input, or with the presence of active CAN C communications. The FDCM will power down when the vehicle ignition switch transitions from ON to OFF, or there are no CAN C messages, or there are no system requirements that dictate the controller to remain active START-UP DIAGNOSTICS When the FDCM is activated, the internal circuitry will undergo a diagnostic procedure. The controller will examine all inputs and outputs for short circuits to ground, short circuits to battery and open circuits and will also verify proper CPU and memory operation. If a fault is detected, a message will be sent out over the CAN C bus to the Cluster based Electronic Vehicle Information Center (EVIC) indicating that service is recommended. After passing all diagnostic tests, the controller will receive and process inputs and produce the appropriate outputs. Proper monitoring of the controller inputs and outputs performance will continue. INPUTS/OUTPUTS The following are inputs to the FDCM: - Lateral Accelerometer - Transfer Case Mode Sensor Signal - 3 Direct Battery Feeds - Ignition RUN Sense - Sensor Grounds - Module Grounds - CAN C Bus The following are outputs of the FDCM: - 5V Sensor Supply - Transfer Case Bi-directional Motor Control (A AND B) TRANSFER CASE MODE SENSOR SIGNAL The Transfer Case Mode Sensor Signal Input will provide the FDCM feedback about the position of the transfer case. The mode sensor will be a linear analog position sensor with a 1.4K +/- 20% potentiometer and a 1 K +/- 20% resistor that converts the motor shaft position into a multiplexed voltage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 5238 SLIP CONTROL Slip Control increases torque to the front axle when a relative slip is detected between the front and the rear prop shafts. Slip Control adjusts according to the vehicle speed and allows a permissible slip. Utilizes a closed loop strategy for permissible slip and speed of engagement. STABILITY CONTROL Stability control modifies the torque request based upon the vehicle dynamics under the over-steer and under-steer conditions. It monitors the yaw rate and the lateral acceleration to modify the clutch capacity to bring the vehicle back to a more neutral attitude. Compensates for high load conditions by monitoring the vehicle acceleration and changing the torque capacity. REGENERATIVE BRAKING STRATEGY During the event of regenerative braking the software splits the torque indicated by the signal axle in a ratio of 47:53 front and rear respectively. This torque split is to be modified to achieve optimum efficiency levels during a braking event. MODES OF OPERATION Normal Operation This mode is achieved by the ignition being switched in the RUN position, which powers up the 5V regulator and generates the appropriate RESET for the microprocessor. This mode also includes any required power-up system checks. Shut Down Mode This mode is activated when the ignition switch turned to the off position. The FDCM will perform any required Shut Down tasks prior to turning off the 5V regulator. Limp-In Mode This mode is entered when the FDCM has detected an error condition that prevents the system from performing its' required task. The FDCM operation will vary depending from modified operation to total system shut down based on the failure that has occurred. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal Control Module: Service and Repair Final Drive Control Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect the module electrical connectors. 3. Using a trim stick C-4755 or equivalent, gently pry back on the retaining tabs on the mounting plate and remove module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal > Page 5241 Control Module: Service and Repair Final Drive Control Module - Installation INSTALLATION 1. Place the final drive control module in its location on the mounting plate and firmly snap into place. 2. Connect the electrical connectors. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Differential Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Differential, Transfer Case > Differential Fluid Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5247 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Fluid - Transfer Case: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5252 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications MP3010 ............................................................................................................................................... ......................................................... 2.85 pts (1.35L) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 5255 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid ............................................................................................................................. ........................................................... Mopar ATF +4 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 5256 Fluid - Transfer Case: Service and Repair STANDARD PROCEDURE - FLUID DRAIN/REFILL The fill and drain plugs are both in the rear case. 1. Raise vehicle. Ensure that the vehicle is level on the hoist. 2. Position drain pan under transfer case. 3. Remove fill plug (1) and drain plug (2) and drain lubricant completely. 4. Install drain plug (2) and tighten plug to 27 Nm (20 ft. lbs.). 5. Fill transfer case to bottom edge of fill plug opening with MOPAR(R) ATF+4 6. Install and tighten fill plug (1) and tighten plug to 27 Nm (20 ft. lbs.). 7. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description Four Wheel Drive Indicator Lamp: Description and Operation 4WD Indicator - Description 4WD INDICATOR A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD indicator is located below the minor gauge set on the left side of the cluster. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 5261 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Low Indicator - Description 4WD LOW INDICATOR A 4WD low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD low indicator is located below the minor gauge set on the left side of the cluster. The 4WD low indicator consists of a stencil-like cutout of the text 4LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD low indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 5262 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Indicator - Operation 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-on message from the FCM, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the 4WD indicator will be turned ON, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD mode is engaged. The FCM then sends the proper lamp-on or lamp-off message to the instrument cluster also known as the Cab Compartment Node (CCN). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transfer case shift motor/mode sensor, the FCM, the CCN, the CAN data bus or the electronic communication related to 4WD indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 5263 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Low Indicator - Operation 4WD LOW INDICATOR The 4WD low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The 4WD low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the 4WD low indicator for the following reasons: - 4WD Low Indicator Lamp-On Message- Each time the cluster receives an electronic 4WD low indicator lamp-on message from the FCM, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the 4WD low indicator turns on, then off again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The FCM then sends the proper lamp-on or lamp-off message to the Instrument Cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the 4WD low indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transfer case shift motor/mode sensor, the FCM, the CCN, the CAN data bus or the electronic communication related to 4WD low indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5267 Four Wheel Drive Selector Switch: Diagrams Connector - (INSTRUMENT PANEL) 10 WAY SWITCH-TRANSFER CASE SELECTOR - (INSTRUMENT PANEL) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 5271 Gear Sensor/Switch: Diagrams Connector - (ENGINE) 8 WAY ASSEMBLY-SHIFT MOTOR/MODE SENSOR - (ENGINE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > Mode Sensor - Description Gear Sensor/Switch: Description and Operation Mode Sensor - Description DESCRIPTION The transfer case encoder (3) provides the Drive Train Control Module (DTCM) feedback about the position of the transfer case. The sensor consists of a linear analog position sensor that converts the motor output shaft position into a DC signal. The sensor may rotate a full 360 degrees. When the DTCM is not in sleep mode, it must supply 5 VDC (+/- 0.5 v) to the sensor and monitor the shift motor position. The sensor position is monitored when the ignition is in the RUN position and for 10 seconds after the ignition is turned to the OFF position. The sensor is mechanically linked to the shaft of the cam allowing the transfer case to shift. The mode sensor draws less than 20 mA of current during operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > Mode Sensor - Description > Page 5274 Gear Sensor/Switch: Description and Operation Mode Sensor - Operation OPERATION During normal vehicle operation, the DTCM monitors the mode sensor outputs at least every 2 milliseconds when the shift motor is stationary or active. The mode sensor position will be considered invalid by the DTCM if the voltage is greater than 4.75 V or if it is less than 0.25 V. NOTE: All the parameter voltages referred to in the following information are calibrated items in the controller software and are subject to change. The DTCM shall consider Transfer Case position based on the MODE SENSOR VOLTAGES table listed below: MODE SENSOR VOLTAGES Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Mode Sensor - Removal Gear Sensor/Switch: Service and Repair Mode Sensor - Removal REMOVAL 1. Remove the wiring harness electrical connector from the encoder. 2. Remove the screws securing the encoder to the rear transfer case housing. 3. Remove the encoder (1) from the transfer case (2). 4. Remove the O-ring seal (1) from the encoder (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Mode Sensor - Removal > Page 5277 Gear Sensor/Switch: Service and Repair Mode Sensor - Installation INSTALLATION 1. Install a NEW O-ring seal (1) onto the encoder (2). NOTE: Before installing the encoder onto the transfer case, be certain to align the encoder shaft to the shift shaft and the dowel on the encoder to the hole in the case accordingly. 2. Install the encoder (1) onto the rear transfer case housing (2). 3. Install the encoder screws. Tighten the screws to 7 Nm (62 in.lbs.). 4. Install the electrical wiring harness connector onto the encoder. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description Four Wheel Drive Indicator Lamp: Description and Operation 4WD Indicator - Description 4WD INDICATOR A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD indicator is located below the minor gauge set on the left side of the cluster. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 5283 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Low Indicator - Description 4WD LOW INDICATOR A 4WD low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD low indicator is located below the minor gauge set on the left side of the cluster. The 4WD low indicator consists of a stencil-like cutout of the text 4LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD low indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 5284 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Indicator - Operation 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-on message from the FCM, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the 4WD indicator will be turned ON, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD mode is engaged. The FCM then sends the proper lamp-on or lamp-off message to the instrument cluster also known as the Cab Compartment Node (CCN). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transfer case shift motor/mode sensor, the FCM, the CCN, the CAN data bus or the electronic communication related to 4WD indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 5285 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Low Indicator - Operation 4WD LOW INDICATOR The 4WD low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The 4WD low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the 4WD low indicator for the following reasons: - 4WD Low Indicator Lamp-On Message- Each time the cluster receives an electronic 4WD low indicator lamp-on message from the FCM, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the 4WD low indicator turns on, then off again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The FCM then sends the proper lamp-on or lamp-off message to the Instrument Cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the 4WD low indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transfer case shift motor/mode sensor, the FCM, the CCN, the CAN data bus or the electronic communication related to 4WD low indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Service 4WD Indicator - Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Service 4WD Indicator Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located below the minor gauge set on the left side of the cluster. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Service 4WD Indicator - Description > Page 5290 Malfunction Indicator Lamp - Transfer Case: Description and Operation Service 4WD Indicator Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Front Control Module (FCM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the FCM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-on message from the FCM, the service 4WD indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-off messages from the FCM for 10 seconds, the service 4WD indicator is illuminated by the cluster to indicate a loss of FCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the FCM. - Self Test - Each time the cluster is put through the self test, the service 4WD indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The FCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the FCM, the CCN, the CAN data bus or the electronic communication related to service 4WD indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Service 4WD Indicator - Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Service 4WD Indicator Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located below the minor gauge set on the left side of the cluster. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Service 4WD Indicator - Description > Page 5295 Malfunction Indicator Lamp - Transfer Case: Description and Operation Service 4WD Indicator Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Front Control Module (FCM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the FCM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-on message from the FCM, the service 4WD indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-off messages from the FCM for 10 seconds, the service 4WD indicator is illuminated by the cluster to indicate a loss of FCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the FCM. - Self Test - Each time the cluster is put through the self test, the service 4WD indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The FCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the FCM, the CCN, the CAN data bus or the electronic communication related to service 4WD indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way Control Module: Diagrams Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way Connector C1 (HEV) - (HEADLAMP AND DASH) 16 WAY MODULE-FINAL DRIVE CONTROL (HEV) - (HEADLAMP AND DASH) 16 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way > Page 5301 Control Module: Diagrams Final Drive Control Module C2 (HEV) (Headlamp And Dash) 4 Way Connector C2 (HEV) - (HEADLAMP AND DASH) 4 WAY MODULE-FINAL DRIVE CONTROL (HEV) - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description Control Module: Description and Operation Final Drive Control Module - Description DESCRIPTION FDCM (Final Drive Control Module) is an electronic module that controls the shifting of the AWD new "Active on Demand" MP3010 single speed transfer case. This plastic cased module is packaged in the (Pedal Assembly) MAG bracket for the HB/HG HEV vehicle. Communication is via the CAN serial bus. The FDCM is installed inside the passenger compartment behind the driver side knee bolster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 5304 Control Module: Description and Operation Final Drive Control Module - Operation OPERATION POWER UP/DOWN The Final Drive Control Module (FDCM) will power up with an OFF/ON transition of the hard wired ignition switch input, or with the presence of active CAN C communications. The FDCM will power down when the vehicle ignition switch transitions from ON to OFF, or there are no CAN C messages, or there are no system requirements that dictate the controller to remain active START-UP DIAGNOSTICS When the FDCM is activated, the internal circuitry will undergo a diagnostic procedure. The controller will examine all inputs and outputs for short circuits to ground, short circuits to battery and open circuits and will also verify proper CPU and memory operation. If a fault is detected, a message will be sent out over the CAN C bus to the Cluster based Electronic Vehicle Information Center (EVIC) indicating that service is recommended. After passing all diagnostic tests, the controller will receive and process inputs and produce the appropriate outputs. Proper monitoring of the controller inputs and outputs performance will continue. INPUTS/OUTPUTS The following are inputs to the FDCM: - Lateral Accelerometer - Transfer Case Mode Sensor Signal - 3 Direct Battery Feeds - Ignition RUN Sense - Sensor Grounds - Module Grounds - CAN C Bus The following are outputs of the FDCM: - 5V Sensor Supply - Transfer Case Bi-directional Motor Control (A AND B) TRANSFER CASE MODE SENSOR SIGNAL The Transfer Case Mode Sensor Signal Input will provide the FDCM feedback about the position of the transfer case. The mode sensor will be a linear analog position sensor with a 1.4K +/- 20% potentiometer and a 1 K +/- 20% resistor that converts the motor shaft position into a multiplexed voltage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 5305 SLIP CONTROL Slip Control increases torque to the front axle when a relative slip is detected between the front and the rear prop shafts. Slip Control adjusts according to the vehicle speed and allows a permissible slip. Utilizes a closed loop strategy for permissible slip and speed of engagement. STABILITY CONTROL Stability control modifies the torque request based upon the vehicle dynamics under the over-steer and under-steer conditions. It monitors the yaw rate and the lateral acceleration to modify the clutch capacity to bring the vehicle back to a more neutral attitude. Compensates for high load conditions by monitoring the vehicle acceleration and changing the torque capacity. REGENERATIVE BRAKING STRATEGY During the event of regenerative braking the software splits the torque indicated by the signal axle in a ratio of 47:53 front and rear respectively. This torque split is to be modified to achieve optimum efficiency levels during a braking event. MODES OF OPERATION Normal Operation This mode is achieved by the ignition being switched in the RUN position, which powers up the 5V regulator and generates the appropriate RESET for the microprocessor. This mode also includes any required power-up system checks. Shut Down Mode This mode is activated when the ignition switch turned to the off position. The FDCM will perform any required Shut Down tasks prior to turning off the 5V regulator. Limp-In Mode This mode is entered when the FDCM has detected an error condition that prevents the system from performing its' required task. The FDCM operation will vary depending from modified operation to total system shut down based on the failure that has occurred. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal Control Module: Service and Repair Final Drive Control Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect the module electrical connectors. 3. Using a trim stick C-4755 or equivalent, gently pry back on the retaining tabs on the mounting plate and remove module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal > Page 5308 Control Module: Service and Repair Final Drive Control Module - Installation INSTALLATION 1. Place the final drive control module in its location on the mounting plate and firmly snap into place. 2. Connect the electrical connectors. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Input Shaft Seal - Installation Seals and Gaskets: Service and Repair Front Input Shaft Seal - Installation INSTALLATION NOTE: Lubricate all seals with MOPAR(R) ATF+4 prior to installation. 1. Using Driver handle C-4171 (1) and Seal Installer 8841 (2) install the front input shaft seal. 2. Install the transfer case into the vehicle.See: Service and Repair/Removal and Replacement/MP3010 Transfer Case - Installation 3. Check the transfer case fluid. See: Service and Repair/Procedures/MP3010 Transfer Case - Fluid Drain and Refill. Correct as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Input Shaft Seal - Installation > Page 5313 Seals and Gaskets: Service and Repair Front Output Shaft Seal - Removal REMOVAL 1. Raise vehicle. 2. Remove the front propeller shaft See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Drive Shaft - Removal. 3. Remove the front propeller shaft seal boot (1) retaining clamp (2). 4. Remove the front propeller shaft seal boot (2) from the front output shaft seal slinger (3). 5. Using a suitable hammer and chisel, strike the seal slinger (2) with the chisel as shown in three, equally spaced locations. NOTE: The indentations (2) should appear as shown here. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Input Shaft Seal - Installation > Page 5314 6. Remove the seal slinger (1) from the front output shaft. 7. Remove the front output shaft seal slinger (1) from the output shaft (2). 8. Remove the front output shaft seal (1) from the transfer case bore (2) using a suitable tool or a screw mounted in a slide hammer. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Input Shaft Seal - Installation > Page 5315 Seals and Gaskets: Service and Repair Front Output Shaft Seal - Installation INSTALLATION NOTE: Lubricate all seals with MOPAR(R) ATF+4 prior to installation. 1. Install the new front output shaft seal (1) into position in the transfer case bore (2). 2. Install the new front output shaft seal with Installer 10117 (1). 3. Install the new front output shaft seal slinger (1) into position on the output shaft (2). 4. Install the front output shaft seal slinger with Installer 10117. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Input Shaft Seal - Installation > Page 5316 5. Install the seal boot (2) onto the seal slinger (3) 6. Install a new seal boot clamp onto the seal boot, at the seal slinger, and tighten the clamp with Crimp Tool C-4975A 7. Install the front propeller shaft. See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Drive Shaft - Installation 8. Check the transfer case fluid level and correct as necessary. See: Service and Repair/Procedures/MP3010 Transfer Case - Fluid Drain and Refill Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Input Shaft Seal - Installation > Page 5317 Seals and Gaskets: Service and Repair Front Input Shaft Seal - Removal REMOVAL 1. Remove the transfer case from the vehicle.See: Service and Repair/Removal and Replacement/MP3010 Transfer Case - Removal. 2. Remove the input shaft seal using Seal Remover 7794-A (1) and Slide Hammer C-637 (2). Front Input Shaft Seal - Installation INSTALLATION NOTE: Lubricate all seals with MOPAR(R) ATF+4 prior to installation. 1. Using Driver handle C-4171 (1) and Seal Installer 8841 (2) install the front input shaft seal. 2. Install the transfer case into the vehicle.See: Service and Repair/Removal and Replacement/MP3010 Transfer Case - Installation 3. Check the transfer case fluid. See: Service and Repair/Procedures/MP3010 Transfer Case - Fluid Drain and Refill. Correct as necessary. Front Output Shaft Seal - Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Input Shaft Seal - Installation > Page 5318 1. Raise vehicle. 2. Remove the front propeller shaft See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Drive Shaft - Removal. 3. Remove the front propeller shaft seal boot (1) retaining clamp (2). 4. Remove the front propeller shaft seal boot (2) from the front output shaft seal slinger (3). 5. Using a suitable hammer and chisel, strike the seal slinger (2) with the chisel as shown in three, equally spaced locations. NOTE: The indentations (2) should appear as shown here. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Input Shaft Seal - Installation > Page 5319 6. Remove the seal slinger (1) from the front output shaft. 7. Remove the front output shaft seal slinger (1) from the output shaft (2). 8. Remove the front output shaft seal (1) from the transfer case bore (2) using a suitable tool or a screw mounted in a slide hammer. Front Output Shaft Seal - Installation INSTALLATION NOTE: Lubricate all seals with MOPAR(R) ATF+4 prior to installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Input Shaft Seal - Installation > Page 5320 1. Install the new front output shaft seal (1) into position in the transfer case bore (2). 2. Install the new front output shaft seal with Installer 10117 (1). 3. Install the new front output shaft seal slinger (1) into position on the output shaft (2). 4. Install the front output shaft seal slinger with Installer 10117. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Input Shaft Seal - Installation > Page 5321 5. Install the seal boot (2) onto the seal slinger (3) 6. Install a new seal boot clamp onto the seal boot, at the seal slinger, and tighten the clamp with Crimp Tool C-4975A 7. Install the front propeller shaft. See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Drive Shaft - Installation 8. Check the transfer case fluid level and correct as necessary. See: Service and Repair/Procedures/MP3010 Transfer Case - Fluid Drain and Refill Rear Output Shaft Seal - Removal REMOVAL 1. Remove the rear propeller shaft. See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Drive Shaft - Removal. 2. Remove the rear output shaft seal (1) from the transfer case (2) with a suitable pry tool or a screw mounted in a slide hammer. Rear Output Shaft Seal - Installation INSTALLATION NOTE: Lubricate all seals with MOPAR(R) ATF+4 prior to installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Front Input Shaft Seal - Installation > Page 5322 1. Install the rear output shaft oil seal using Seal Installer C-3972-A (1) and Driver Handle C-4171 (2). 2. Install the rear propeller shaft. See: Drive/Propeller Shafts, Bearings and Joints/Drive/Propeller Shaft/Service and Repair/Removal and Replacement/Drive Shaft - Installation. 3. Check the transfer case fluid level. See: Service and Repair/Procedures/MP3010 Transfer Case - Fluid Drain and Refill Correct as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5327 Four Wheel Drive Selector Switch: Diagrams Connector - (INSTRUMENT PANEL) 10 WAY SWITCH-TRANSFER CASE SELECTOR - (INSTRUMENT PANEL) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 5331 Gear Sensor/Switch: Diagrams Connector - (ENGINE) 8 WAY ASSEMBLY-SHIFT MOTOR/MODE SENSOR - (ENGINE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > Mode Sensor - Description Gear Sensor/Switch: Description and Operation Mode Sensor - Description DESCRIPTION The transfer case encoder (3) provides the Drive Train Control Module (DTCM) feedback about the position of the transfer case. The sensor consists of a linear analog position sensor that converts the motor output shaft position into a DC signal. The sensor may rotate a full 360 degrees. When the DTCM is not in sleep mode, it must supply 5 VDC (+/- 0.5 v) to the sensor and monitor the shift motor position. The sensor position is monitored when the ignition is in the RUN position and for 10 seconds after the ignition is turned to the OFF position. The sensor is mechanically linked to the shaft of the cam allowing the transfer case to shift. The mode sensor draws less than 20 mA of current during operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > Mode Sensor - Description > Page 5334 Gear Sensor/Switch: Description and Operation Mode Sensor - Operation OPERATION During normal vehicle operation, the DTCM monitors the mode sensor outputs at least every 2 milliseconds when the shift motor is stationary or active. The mode sensor position will be considered invalid by the DTCM if the voltage is greater than 4.75 V or if it is less than 0.25 V. NOTE: All the parameter voltages referred to in the following information are calibrated items in the controller software and are subject to change. The DTCM shall consider Transfer Case position based on the MODE SENSOR VOLTAGES table listed below: MODE SENSOR VOLTAGES Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Mode Sensor - Removal Gear Sensor/Switch: Service and Repair Mode Sensor - Removal REMOVAL 1. Remove the wiring harness electrical connector from the encoder. 2. Remove the screws securing the encoder to the rear transfer case housing. 3. Remove the encoder (1) from the transfer case (2). 4. Remove the O-ring seal (1) from the encoder (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Mode Sensor - Removal > Page 5337 Gear Sensor/Switch: Service and Repair Mode Sensor - Installation INSTALLATION 1. Install a NEW O-ring seal (1) onto the encoder (2). NOTE: Before installing the encoder onto the transfer case, be certain to align the encoder shaft to the shift shaft and the dowel on the encoder to the hole in the case accordingly. 2. Install the encoder (1) onto the rear transfer case housing (2). 3. Install the encoder screws. Tighten the screws to 7 Nm (62 in.lbs.). 4. Install the electrical wiring harness connector onto the encoder. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Transfer Case Encoder Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Transfer Case Encoder > Page 5342 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Locations > Transfer Case Encoder > Page 5343 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Shift Motor/Mode Sensor Assembly (Engine) 8 Way Transfer Case Actuator: Diagrams Shift Motor/Mode Sensor Assembly (Engine) 8 Way Connector - (ENGINE) 8 WAY ASSEMBLY-SHIFT MOTOR/MODE SENSOR - (ENGINE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Shift Motor/Mode Sensor Assembly (Engine) 8 Way > Page 5346 Transfer Case Actuator: Diagrams Transfer Case Encoder (HEV) (Engine) 3 Way Connector (HEV) - (ENGINE) 3 WAY ENCODER-TRANSFER CASE (HEV) - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Shift Motor/Mode Sensor Assembly (Engine) 8 Way > Page 5347 Transfer Case Actuator: Diagrams Transfer Case Motor (HEV) Engine 4 Way Connector (HEV) - ENGINE 4 WAY MOTOR-TRANSFER CASE (HEV) - ENGINE 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > Shift Motor - Description Transfer Case Actuator: Description and Operation Shift Motor - Description DESCRIPTION The overall function of the shift motor (1) is an electromechanical device consisting of a DC permanent magnet motor and a position holding brake. The shift motors function is to move and lock a gear that moves the range fork and clutch lever found in the transfer case. This allows the transfer case to be shifted electrically to multiple operating positions (4WD AUTO, 4WD LOW and 2WD). The operating current of the shift motor under stall conditions is 30 amps maximum, at 22° C (72° F) with 13.5 volts, at the motor leads. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > Shift Motor - Description > Page 5350 Transfer Case Actuator: Description and Operation Shift Motor - Operation OPERATION Shifting in the transfer case occurs when a Pulse Width Modulated (PWM) voltage is supplied to the shift motor (1) by the Final Drive Control Module (FDCM). A linear analog position sensor (encoder) (3) located on the rear transfer case housing and provides the FDCM with the motor's angular, rotational position. With this information, the FDCM continuously knows the position of the motor, and therefore allows it to accurately control the operation of the motor, including voltage polarity which is used to control motor direction. The electronically controlled wet clutch pack uses an electric motor to actuate an internal gear train, clutch cam, and low range barrel cam. The clutch cam actuates the clutch levers that apply normal force to the multi-disc wet clutch pack. The clutch discs are alternately splined to the front and rear outputs. When normal force is applied to this clutch pack, torque is transferred to equalize speed differences between the front and rear axles. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Shift Motor - Removal Transfer Case Actuator: Service and Repair Shift Motor - Removal REMOVAL NOTE: New shift motor assemblies are shipped in the NEUTRAL position. If a new shift motor assembly must be installed, it will be necessary to shift the transfer case to the NEUTRAL position prior to motor installation. 1. Disconnect the electrical connector from the shift motor. 2. Remove the bolts holding the shift motor to the transfer case. 3. Remove the shift motor (1) from the transfer case. 4. Remove the O-ring seal (2) from the shift motor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Shift Motor - Removal > Page 5353 Transfer Case Actuator: Service and Repair Shift Motor - Installation INSTALLATION NOTE: Before installing the shift motor onto the transfer case, make certain that the shift motor shaft aligns with the transfer case worm shaft accordingly. 1. Install a NEW shift motor o-ring seal (2) onto the shift motor (1). 2. Install the shift motor (1) onto the transfer case. 3. Install the shift motor bolts. Tighten the shift motor bolts to 13 Nm (9 ft. lbs.). 4. Install the electrical wiring harness connector onto the shift motor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5363 Shift Interlock Solenoid: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SOLENOID-BRAKE TRANSMISSION SHIFT INTERLOCK - (INSTRUMENT PANEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Transfer Case Encoder Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Transfer Case Encoder > Page 5372 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Locations > Transfer Case Encoder > Page 5373 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Shift Motor/Mode Sensor Assembly (Engine) 8 Way Transfer Case Actuator: Diagrams Shift Motor/Mode Sensor Assembly (Engine) 8 Way Connector - (ENGINE) 8 WAY ASSEMBLY-SHIFT MOTOR/MODE SENSOR - (ENGINE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Shift Motor/Mode Sensor Assembly (Engine) 8 Way > Page 5376 Transfer Case Actuator: Diagrams Transfer Case Encoder (HEV) (Engine) 3 Way Connector (HEV) - (ENGINE) 3 WAY ENCODER-TRANSFER CASE (HEV) - (ENGINE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Shift Motor/Mode Sensor Assembly (Engine) 8 Way > Page 5377 Transfer Case Actuator: Diagrams Transfer Case Motor (HEV) Engine 4 Way Connector (HEV) - ENGINE 4 WAY MOTOR-TRANSFER CASE (HEV) - ENGINE 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > Shift Motor - Description Transfer Case Actuator: Description and Operation Shift Motor - Description DESCRIPTION The overall function of the shift motor (1) is an electromechanical device consisting of a DC permanent magnet motor and a position holding brake. The shift motors function is to move and lock a gear that moves the range fork and clutch lever found in the transfer case. This allows the transfer case to be shifted electrically to multiple operating positions (4WD AUTO, 4WD LOW and 2WD). The operating current of the shift motor under stall conditions is 30 amps maximum, at 22° C (72° F) with 13.5 volts, at the motor leads. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Description and Operation > Shift Motor - Description > Page 5380 Transfer Case Actuator: Description and Operation Shift Motor - Operation OPERATION Shifting in the transfer case occurs when a Pulse Width Modulated (PWM) voltage is supplied to the shift motor (1) by the Final Drive Control Module (FDCM). A linear analog position sensor (encoder) (3) located on the rear transfer case housing and provides the FDCM with the motor's angular, rotational position. With this information, the FDCM continuously knows the position of the motor, and therefore allows it to accurately control the operation of the motor, including voltage polarity which is used to control motor direction. The electronically controlled wet clutch pack uses an electric motor to actuate an internal gear train, clutch cam, and low range barrel cam. The clutch cam actuates the clutch levers that apply normal force to the multi-disc wet clutch pack. The clutch discs are alternately splined to the front and rear outputs. When normal force is applied to this clutch pack, torque is transferred to equalize speed differences between the front and rear axles. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Shift Motor - Removal Transfer Case Actuator: Service and Repair Shift Motor - Removal REMOVAL NOTE: New shift motor assemblies are shipped in the NEUTRAL position. If a new shift motor assembly must be installed, it will be necessary to shift the transfer case to the NEUTRAL position prior to motor installation. 1. Disconnect the electrical connector from the shift motor. 2. Remove the bolts holding the shift motor to the transfer case. 3. Remove the shift motor (1) from the transfer case. 4. Remove the O-ring seal (2) from the shift motor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Service and Repair > Shift Motor - Removal > Page 5383 Transfer Case Actuator: Service and Repair Shift Motor - Installation INSTALLATION NOTE: Before installing the shift motor onto the transfer case, make certain that the shift motor shaft aligns with the transfer case worm shaft accordingly. 1. Install a NEW shift motor o-ring seal (2) onto the shift motor (1). 2. Install the shift motor (1) onto the transfer case. 3. Install the shift motor bolts. Tighten the shift motor bolts to 13 Nm (9 ft. lbs.). 4. Install the electrical wiring harness connector onto the shift motor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Tow/Haul Indicator - Description Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator - Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. The tow/haul indicator is located below the minor gauge set on the left side of the cluster. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information > Description and Operation > Tow/Haul Indicator - Description > Page 5390 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator - Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-on message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - self Test - Each time the cluster is put through the self test, the tow/haul indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transmission control system, the PCM, the CCN, the CAN data bus or the electronic communication related to tow/haul indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description Four Wheel Drive Indicator Lamp: Description and Operation 4WD Indicator - Description 4WD INDICATOR A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD indicator is located below the minor gauge set on the left side of the cluster. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 5396 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Low Indicator - Description 4WD LOW INDICATOR A 4WD low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD low indicator is located below the minor gauge set on the left side of the cluster. The 4WD low indicator consists of a stencil-like cutout of the text 4LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD low indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 5397 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Indicator - Operation 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-on message from the FCM, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the 4WD indicator will be turned ON, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD mode is engaged. The FCM then sends the proper lamp-on or lamp-off message to the instrument cluster also known as the Cab Compartment Node (CCN). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transfer case shift motor/mode sensor, the FCM, the CCN, the CAN data bus or the electronic communication related to 4WD indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 5398 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Low Indicator - Operation 4WD LOW INDICATOR The 4WD low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The 4WD low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the 4WD low indicator for the following reasons: - 4WD Low Indicator Lamp-On Message- Each time the cluster receives an electronic 4WD low indicator lamp-on message from the FCM, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the 4WD low indicator turns on, then off again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The FCM then sends the proper lamp-on or lamp-off message to the Instrument Cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the 4WD low indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transfer case shift motor/mode sensor, the FCM, the CCN, the CAN data bus or the electronic communication related to 4WD low indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Service 4WD Indicator - Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Service 4WD Indicator Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located below the minor gauge set on the left side of the cluster. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Service 4WD Indicator - Description > Page 5403 Malfunction Indicator Lamp - Transfer Case: Description and Operation Service 4WD Indicator Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Front Control Module (FCM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the FCM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-on message from the FCM, the service 4WD indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-off messages from the FCM for 10 seconds, the service 4WD indicator is illuminated by the cluster to indicate a loss of FCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the FCM. - Self Test - Each time the cluster is put through the self test, the service 4WD indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The FCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the FCM, the CCN, the CAN data bus or the electronic communication related to service 4WD indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description Control Module: Description and Operation Transmission Control Module - Description DESCRIPTION RFE - RLE TRANSMISSIONS The Transmission Control Module (TCM) is a sub-module within the Powertrain Control Module (PCM). The PCM is located on the right inner fender. EVT AHS-T TRANSMISSION TEHCM MOUNTING BOLTS On vehicles equipped with the AHS-T HEV transmission the TCM is imbedded into the Transmission Electronic Hydraulic Control Module (TECHM) that is mounted to the valve body and is not serviceable, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 5410 Control Module: Description and Operation Transmission Control Module - Operation OPERATION The Transmission Control Module (TCM) controls all electronic operations of the transmission. The TCM receives information regarding vehicle operation from both direct and indirect inputs, and selects the operational mode of the transmission. Direct inputs are hard wired to, and used specifically by the TCM. Indirect inputs are shared with the TCM via the vehicle communication bus. Some examples of direct inputs to the TCM are: - Battery (B+) voltage - Ignition "ON" voltage - Transmission Control Relay (Switched B+) (if equipped) - Throttle Position Sensor - Crankshaft Position Sensor - Transmission Range Sensor - Pressure Switches - Transmission Temperature Sensor - Input Shaft Speed Sensor - Output Shaft Speed Sensor - Line Pressure Sensor Some examples of indirect inputs to the TCM are: - Engine/Body Identification - Manifold Pressure - Target Idle - Torque Reduction Confirmation - Engine Coolant Temperature - Ambient/Battery Temperature - Scan Tool Communication Based on the information received from these various inputs, the TCM determines the appropriate shift schedule and shift points, depending on the present operating conditions and driver demand. This is possible through the control of various direct and indirect outputs. Some examples of TCM direct outputs are: - Transmission Control Relay - Solenoids - Torque Reduction Request Some examples of TCM indirect outputs are: - Transmission Temperature (to PCM) - PRNDL Position (to cluster/CCN) In addition to monitoring inputs and controlling outputs, the TCM has other important responsibilities and functions: - Storing and maintaining Clutch Volume Indexes (CVI) - Storing and selecting appropriate Shift Schedules - System self-diagnostics - Diagnostic capabilities (with scan tool) NOTE: If the TCM has been replaced, the "Quick Learn Procedure" must be performed. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Programming and Relearning/TCM Quick Learn BATTERY FEED A fused, direct battery feed to the TCM is used for continuous power. This battery voltage is necessary to retain memory in the TCM. When the battery (B+) is disconnected, this memory is lost. When the battery (B+) is restored, this memory loss is detected by the TCM and a Diagnostic Trouble Code (DTC) is set. CLUTCH VOLUME INDEXES (CVI) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 5411 An important function of the TCM is to monitor Clutch Volume Indexes (CVI). CVIs represent the volume of fluid needed to compress a clutch pack. The TCM monitors gear ratio changes by monitoring the Input and Output Speed Sensors. The Input, or Turbine Speed Sensor sends an electrical signal to the TCM that represents input shaft rpm. The Output Speed Sensor provides the TCM with output shaft speed information. By comparing the two inputs, the TCM can determine transmission gear position. This is important to the CVI calculation because the TCM determines CVIs by monitoring how long it takes for a gear change to occur. Gear ratios can be determined by using the Scan Tool and reading the Input/Output Speed Sensor values in the "Monitors" display. Gear ratio can be obtained by dividing the Input Speed Sensor value by the Output Speed Sensor value. For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the TCM can determine that the gear ratio is 2:1. In direct drive (3rd gear), the gear ratio changes to 1:1. The gear ratio changes as clutches are applied and released. By monitoring the length of time it takes for the gear ratio to change following a shift request, the TCM can determine the volume of fluid used to apply or release a friction element. The volume of transmission fluid needed to apply the friction elements are continuously updated for adaptive controls. As friction material wears, the volume of fluid need to apply the element increases. Certain mechanical problems within the input clutch assembly can cause inadequate or out-of-range element volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions. The following charts identifies the appropriate clutch volumes and when they are monitored/updated: 42RLE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 5412 545RFE EVT AHS-T SHIFT SCHEDULES As mentioned earlier, the TCM has programming that allows it to select a variety of shift schedules. Shift schedule selection is dependent on the following: - Shift lever position - Throttle position - Engine load - Fluid temperature - Software level As driving conditions change, the TCM appropriately adjusts the shift schedule. Refer to the following chart to determine the appropriate operation expected, depending on driving conditions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > Transmission Control Module - Description > Page 5413 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures Control Module: Procedures STANDARD PROCEDURE - RESOLVER LEARN RESOLVER OFFSET LEARN TRIGGER EVT AHS-T TRANSMISSION The Resolver Offset Learn Trigger Procedure requires the use of a scan tool. This program allows the electronic variable transmission (EVT) AHS-T to re-calibrate itself. This will provide the proper transmission operation. The resolver offset learn procedure should be performed if any of the following procedures are performed: - Transmission Assembly Replacement - Transmission Electronic Hydraulic Control Module (TEHCM) Replacement - Flashing the TCM - Electric Motors Replacement - Valve Body Replacement or Recondition To perform the Resolver Offset Learn Trigger Procedure, the following conditions must be met: - The brakes must be applied - The engine speed must be above 500 rpm - The shift lever position must stay in PARK until prompted to shift. - The calculated oil temperature must be above 15° C (60° F) and below 93° C (200° F) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 5416 Control Module: Removal and Replacement Transmission Control Module - Removal REMOVAL WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. NOTE: If the TECHM is being flashed, removed or replaced, it is necessary to perform the Resolver Offset Learn Trigger procedure using the scan tool. 1. Hoist and support vehicle on safety stands. 2. Place a large diameter shallow drain pan beneath the transmission pan. 3. Remove the drain plug, if equipped. 4. Remove the auxiliary oil pump mounting bolts (1). 5. Remove the auxiliary oil pump (2). 6. Remove the transmission oil pan (1), the primary oil filter (2) and the auxiliary oil filter (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 5417 7. Lift up the passage sleeve locking tab (1). Remove the passage sleeve by gripping firmly on two ends and pulling the sleeve away. 8. Disconnect the TEHCM 2-way electrical jumper connector (1) from the internal transmission harness. 9. Disconnect the TEHCM electrical connector (1) from the valve body (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 5418 10. Remove the TEHCM side mounting bolts (1) and main mounting bolts (2) from the valve body. 11. Disconnect the TEHCM jumper harness. 12. If necessary remove the TECHM filter screen (1). Transmission Control Module - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 5419 INSTALLATION WARNING: Be certain the procedure for the high voltage check-out has been performed and the service disconnect has been disconnected. Failure to follow these instructions may result in serious or fatal injury. NOTE: If the TECHM is being flashed, removed or replaced, it is necessary to perform the Resolver Offset Learn Trigger procedure using the scan tool. 1. Install the filter screen onto the TEHCM. TEHCM JUMPER CONNECTOR 2. Connect the TEHCM jumper harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 5420 TEHCM MOUNTING BOLTS 3. Install the TECHM heat sink bolts (1). Tighten the bolts to 7 Nm (62 in.lbs.). 4. Install the TECHM mounting bolts (2). Tighten the bolts to 11 Nm (97 in.lbs.). 5. Connect the 2-way TEHCM electrical connector (1). 6. Connect the TEHCM electrical connector (1) to the valve body. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > Procedures > Page 5421 NOTE: Orientate the alignment tab inside the passage sleeve with the slot in the electrical connector of the control solenoid valve assembly. Push the sleeve straight into the case bore and connector. Do NOT rotate the sleeve at any time. Ensure the sleeve is fully seated into the case. When the sleeve is properly installed, the distance from the case surface to the end of the sleeve should be 14-16 mm. 7. Lubricate the seals on the passage sleeve with DEXRON(R) VI. Install the passage sleeve (2). Push down on the passage locking tab (1) to secure. NOTE: Using a suitable solvent, clean the oil pan and magnet. 8. Install the auxiliary oil filter assembly (3). 9. Install the primary oil filter assembly (2). 10. Install the oil pan gasket and the oil pan (1) onto the transmission case. Install the oil pan bolts. Tighten the oil pan bolts to 27 Nm (19 ft.lbs.). 11. Install the auxiliary oil pump (2) with a NEW gasket. 12. Install the auxiliary oil pump bolts (1). Tighten the bolts to 11 Nm (97 in.lbs.). 13. Check and fill the transmission as necessary with DEXRON(R) VI transmission fluid. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations Transmission Control System Relay: Locations Transmission Control Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5425 Transmission Control System Relay: Diagrams Connector (IN PDC) RELAY-TRANSMISSION CONTROL (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way Control Module: Diagrams Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way Connector C1 (HEV) - (HEADLAMP AND DASH) 16 WAY MODULE-FINAL DRIVE CONTROL (HEV) - (HEADLAMP AND DASH) 16 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Final Drive Control Module C1 (HEV) (Headlamp And Dash) 16 Way > Page 5431 Control Module: Diagrams Final Drive Control Module C2 (HEV) (Headlamp And Dash) 4 Way Connector C2 (HEV) - (HEADLAMP AND DASH) 4 WAY MODULE-FINAL DRIVE CONTROL (HEV) - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description Control Module: Description and Operation Final Drive Control Module - Description DESCRIPTION FDCM (Final Drive Control Module) is an electronic module that controls the shifting of the AWD new "Active on Demand" MP3010 single speed transfer case. This plastic cased module is packaged in the (Pedal Assembly) MAG bracket for the HB/HG HEV vehicle. Communication is via the CAN serial bus. The FDCM is installed inside the passenger compartment behind the driver side knee bolster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 5434 Control Module: Description and Operation Final Drive Control Module - Operation OPERATION POWER UP/DOWN The Final Drive Control Module (FDCM) will power up with an OFF/ON transition of the hard wired ignition switch input, or with the presence of active CAN C communications. The FDCM will power down when the vehicle ignition switch transitions from ON to OFF, or there are no CAN C messages, or there are no system requirements that dictate the controller to remain active START-UP DIAGNOSTICS When the FDCM is activated, the internal circuitry will undergo a diagnostic procedure. The controller will examine all inputs and outputs for short circuits to ground, short circuits to battery and open circuits and will also verify proper CPU and memory operation. If a fault is detected, a message will be sent out over the CAN C bus to the Cluster based Electronic Vehicle Information Center (EVIC) indicating that service is recommended. After passing all diagnostic tests, the controller will receive and process inputs and produce the appropriate outputs. Proper monitoring of the controller inputs and outputs performance will continue. INPUTS/OUTPUTS The following are inputs to the FDCM: - Lateral Accelerometer - Transfer Case Mode Sensor Signal - 3 Direct Battery Feeds - Ignition RUN Sense - Sensor Grounds - Module Grounds - CAN C Bus The following are outputs of the FDCM: - 5V Sensor Supply - Transfer Case Bi-directional Motor Control (A AND B) TRANSFER CASE MODE SENSOR SIGNAL The Transfer Case Mode Sensor Signal Input will provide the FDCM feedback about the position of the transfer case. The mode sensor will be a linear analog position sensor with a 1.4K +/- 20% potentiometer and a 1 K +/- 20% resistor that converts the motor shaft position into a multiplexed voltage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Description and Operation > Final Drive Control Module - Description > Page 5435 SLIP CONTROL Slip Control increases torque to the front axle when a relative slip is detected between the front and the rear prop shafts. Slip Control adjusts according to the vehicle speed and allows a permissible slip. Utilizes a closed loop strategy for permissible slip and speed of engagement. STABILITY CONTROL Stability control modifies the torque request based upon the vehicle dynamics under the over-steer and under-steer conditions. It monitors the yaw rate and the lateral acceleration to modify the clutch capacity to bring the vehicle back to a more neutral attitude. Compensates for high load conditions by monitoring the vehicle acceleration and changing the torque capacity. REGENERATIVE BRAKING STRATEGY During the event of regenerative braking the software splits the torque indicated by the signal axle in a ratio of 47:53 front and rear respectively. This torque split is to be modified to achieve optimum efficiency levels during a braking event. MODES OF OPERATION Normal Operation This mode is achieved by the ignition being switched in the RUN position, which powers up the 5V regulator and generates the appropriate RESET for the microprocessor. This mode also includes any required power-up system checks. Shut Down Mode This mode is activated when the ignition switch turned to the off position. The FDCM will perform any required Shut Down tasks prior to turning off the 5V regulator. Limp-In Mode This mode is entered when the FDCM has detected an error condition that prevents the system from performing its' required task. The FDCM operation will vary depending from modified operation to total system shut down based on the failure that has occurred. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal Control Module: Service and Repair Final Drive Control Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Disconnect the module electrical connectors. 3. Using a trim stick C-4755 or equivalent, gently pry back on the retaining tabs on the mounting plate and remove module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Service and Repair > Final Drive Control Module - Removal > Page 5438 Control Module: Service and Repair Final Drive Control Module - Installation INSTALLATION 1. Place the final drive control module in its location on the mounting plate and firmly snap into place. 2. Connect the electrical connectors. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 5444 Fluid Pressure Sensor/Switch: Diagrams Connector (4.7L/5.7L) - (ENGINE) 4 WAY SENSOR-LINE PRESSURE (4.7L/5.7L) - (ENGINE) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Locations > Page 5448 Overdrive Switch: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SWITCH-TOW/HAUL OVERDRIVE - (INSTRUMENT PANEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Overdrive Lockout Switch - Description Overdrive Switch: Description and Operation Overdrive Lockout Switch - Description DESCRIPTION The tow/haul on control switch is located in the shift lever arm. The switch is a momentary contact device that signals the Powertrain Control Module (PCM) to toggle current status of the overdrive function. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Overdrive Lockout Switch - Description > Page 5451 Overdrive Switch: Description and Operation Overdrive Lockout Switch - Operation OPERATION Tow/haul is only used in the D position. When used while towing, the electronic control module (ECU) commands hybrid system to create more positive axle torque to the wheels. When used while coasting downhill and the vehicle gains speed, the ECU commands the hybrid system to create more negative axle torque to the wheels, helping the vehicle to maintain the correct speed. The Powertrain Control Module (PCM) stores a target speed when the accelerator and brake are released, if vehicle speed increases due to a hill, then additional negative wheel torque is added to the PCMs wheel torque request. The Hybrid Control Processor (HCP) follows the PCMs command and downshifts as required to meet the negative torque request. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Overdrive Lockout Switch - Removal Overdrive Switch: Service and Repair Overdrive Lockout Switch - Removal REMOVAL 1. Using a plastic trim tool (3), remove the tow/haul switch retainer (2) from the gearshift lever (1). 2. Pull the switch (2) outwards to release it from the connector in the lever (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Service and Repair > Overdrive Lockout Switch - Removal > Page 5454 Overdrive Switch: Service and Repair Overdrive Lockout Switch - Installation INSTALLATION NOTE: There is enough slack in the wire to pull out the connector from the lever. 1. Pull the connector (2) out of the lever (1) just enough to grasp it. CAUTION: Be careful not to bend the pins on the tow/haul switch. Use care when installing the switch, as it is not indexed, and can be accidentally installed incorrectly. 2. Install the tow/haul switch (3) into the connector (2). 3. Push the tow/haul switch (3) and wiring into the shift lever (1). 4. Install the tow/haul switch retainer onto the shift lever. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5458 Transmission Position Switch/Sensor: Diagrams Connector (HEV) - (TRANSMISSION SIDE) 12 WAY SENSOR-TRANSMISSION RANGE (HEV) - (TRANSMISSION SIDE) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Description DESCRIPTION The transmission range sensor (2) is located inside the transmission and connects to the mainshaft (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Description and Operation > Transmission Range Sensor - Description > Page 5461 Transmission Position Switch/Sensor: Description and Operation Transmission Range Sensor Operation OPERATION The Transmission Range Sensor (TRS) communicates shift lever position to the TCM as a combination of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear position and shift schedule. There are many possible combinations of open and closed switches (codes). This results in many codes which should never occur. These are called "invalid" codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor - Removal REMOVAL 1. Remove the valve body. See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body Removal. 2. Disconnect the transmission range sensor electrical connector (1). 3. Remove the bolt (1) securing the transmission range sensor (2) to the mainshaft (3). 4. Remove the mainshaft roll pin (1) from the transmission case (2) and remove the mainshaft. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 5464 5. Lower the transmission range sensor (2) and remove the park actuator rod (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 5465 Transmission Position Switch/Sensor: Service and Repair Transmission Range Sensor Installation INSTALLATION 1. Install the park actuator rod (3) into the transmission range sensor (2). 2. Install the mainshaft roll pin (1) to the transmission case (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > Transmission Range Sensor - Removal > Page 5466 3. Position the transmission range sensor (2) into place in the transmission case. 4. Install the mainshaft (3) into the transmission case. 5. Install the transmission range sensor mounting bolt. Tighten the bolt to 8 Nm (71 NOTE: Before install the TEHCM / valve body assembly to the transmission case, be certain the existing gasket is in place. 6. Install the valve body. See: Automatic Transmission/Transaxle/Valve Body/Service and Repair/Removal and Replacement/Valve Body Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 5471 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Input Speed Sensor > Page 5472 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way Transmission Speed Sensor: Diagrams Input Speed Sensor (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-INPUT SPEED - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way > Page 5475 Transmission Speed Sensor: Diagrams Output Speed Sensor (Engine) 2 Way Connector - (ENGINE) 2 WAY SENSOR-OUTPUT SPEED - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input Speed Sensor (Engine) 2 Way > Page 5476 Transmission Speed Sensor: Diagrams Output Speed Sensor (HEV) Engine 2 Way Connector (HEV) - ENGINE 2 WAY SENSOR-OUTPUT SPEED (HEV) - ENGINE 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Oil Temperature Sensor - Description Transmission Temperature Sensor/Switch: Description and Operation Transmission Oil Temperature Sensor - Description DESCRIPTION The transmission temperature sensor is a thermistor that is integral to the Transmission Electronic Hydraulic Control Module (TEHCM). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Oil Temperature Sensor - Description > Page 5481 Transmission Temperature Sensor/Switch: Description and Operation Transmission Oil Temperature Sensor - Operation OPERATION The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmission shift quality, the TCM requires this information to determine which shift schedule to operate in. Calculated Temperature A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a predicted fluid temperature which is calculated from a combination of inputs: - Battery (ambient) temperature. - Engine coolant temperature. - In-gear run time since start-up. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations > Page 5486 Four Wheel Drive Selector Switch: Diagrams Connector - (INSTRUMENT PANEL) 10 WAY SWITCH-TRANSFER CASE SELECTOR - (INSTRUMENT PANEL) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Locations > Page 5490 Gear Sensor/Switch: Diagrams Connector - (ENGINE) 8 WAY ASSEMBLY-SHIFT MOTOR/MODE SENSOR - (ENGINE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > Mode Sensor - Description Gear Sensor/Switch: Description and Operation Mode Sensor - Description DESCRIPTION The transfer case encoder (3) provides the Drive Train Control Module (DTCM) feedback about the position of the transfer case. The sensor consists of a linear analog position sensor that converts the motor output shaft position into a DC signal. The sensor may rotate a full 360 degrees. When the DTCM is not in sleep mode, it must supply 5 VDC (+/- 0.5 v) to the sensor and monitor the shift motor position. The sensor position is monitored when the ignition is in the RUN position and for 10 seconds after the ignition is turned to the OFF position. The sensor is mechanically linked to the shaft of the cam allowing the transfer case to shift. The mode sensor draws less than 20 mA of current during operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Description and Operation > Mode Sensor - Description > Page 5493 Gear Sensor/Switch: Description and Operation Mode Sensor - Operation OPERATION During normal vehicle operation, the DTCM monitors the mode sensor outputs at least every 2 milliseconds when the shift motor is stationary or active. The mode sensor position will be considered invalid by the DTCM if the voltage is greater than 4.75 V or if it is less than 0.25 V. NOTE: All the parameter voltages referred to in the following information are calibrated items in the controller software and are subject to change. The DTCM shall consider Transfer Case position based on the MODE SENSOR VOLTAGES table listed below: MODE SENSOR VOLTAGES Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Mode Sensor - Removal Gear Sensor/Switch: Service and Repair Mode Sensor - Removal REMOVAL 1. Remove the wiring harness electrical connector from the encoder. 2. Remove the screws securing the encoder to the rear transfer case housing. 3. Remove the encoder (1) from the transfer case (2). 4. Remove the O-ring seal (1) from the encoder (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Service and Repair > Mode Sensor - Removal > Page 5496 Gear Sensor/Switch: Service and Repair Mode Sensor - Installation INSTALLATION 1. Install a NEW O-ring seal (1) onto the encoder (2). NOTE: Before installing the encoder onto the transfer case, be certain to align the encoder shaft to the shift shaft and the dowel on the encoder to the hole in the case accordingly. 2. Install the encoder (1) onto the rear transfer case housing (2). 3. Install the encoder screws. Tighten the screws to 7 Nm (62 in.lbs.). 4. Install the electrical wiring harness connector onto the encoder. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > ABS Indicator - Description ABS Light: Description and Operation ABS Indicator - Description DESCRIPTION An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. This indicator serves both the standard equipment Rear Wheel Anti-Lock (RWAL) and optional equipment 4-Wheel Anti-Lock (4WAL) brake systems. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The ABS indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Failure of Anti-lock Braking System in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ABS indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation > ABS Indicator - Description > Page 5503 ABS Light: Description and Operation ABS Indicator - Operation OPERATION The ABS indicator gives an indication to the vehicle operator when the ABS system, or a circuit or component of the system is ineffective. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus. The ABS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the ABS indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the ABS indicator illuminates for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - ABS Indicator Lamp-On Message - Each time the cluster receives an electronic ABS indicator lamp-on message from the CAB, the ABS indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch turns to the OFF position, whichever occurs first. Communication Error - If the cluster receives no lamp-on or lamp-off messages from the CAB for five consecutive message cycles, the ABS indicator illuminates. The indicator remains illuminated until the cluster receives a valid message from the CAB, or until the ignition switch turns to the OFF position, whichever occurs first. - Self Test - Each time the instrument cluster is put through the self test, the ABS indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - ABS Diagnostic Test - The ABS indicator blinks on and off by lamp-on and lamp-off messages from the CAB during the performance of the ABS diagnostic tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a system malfunction or that the ABS system has become ineffective. The CAB stores a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ABS indicator fails to light due to an open or short in the cluster ABS indicator circuit, the cluster sends a message notifying the CAB of the condition, then the instrument cluster and the CAB each store a DTC. Use a diagnostic scan tool for proper diagnosis of the antilock brake system, the CAB, the CCN, the CAN data bus or the electronic communication related to ABS indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Brake Pedal Angle Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Locations > Brake Pedal Angle Sensor > Page 5508 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Diagrams > Brake Pedal Angle Sensor (Headlamp And Dash) 6 Way Braking Sensor/Switch: Diagrams Brake Pedal Angle Sensor (Headlamp And Dash) 6 Way Connector - (HEADLAMP AND DASH) 6 WAY SENSOR-BRAKE PEDAL ANGLE - (HEADLAMP AND DASH) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Braking Sensor/Switch > Component Information > Diagrams > Brake Pedal Angle Sensor (Headlamp And Dash) 6 Way > Page 5511 Braking Sensor/Switch: Diagrams Brake Pedal Pressure Sensor (HEV) (Headlamp And Dash) 3 Way Connector (HEV) - (HEADLAMP AND DASH) 3 WAY SENSOR-BRAKE PEDAL PRESSURE (HEV) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Antilock Brake Module (Headlamp And Dash Side) 38 Way Electronic Brake Control Module: Diagrams Antilock Brake Module (Headlamp And Dash Side) 38 Way Connector - (HEADLAMP AND DASH SIDE) 38 WAY MODULE-ANTILOCK BRAKES - (HEADLAMP AND DASH SIDE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Antilock Brake Module (Headlamp And Dash Side) 38 Way > Page 5517 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Antilock Brake Module (Headlamp And Dash Side) 38 Way > Page 5518 Electronic Brake Control Module: Diagrams Antilock Brake Module (HEV) (Headlamp And Dash) 47 Way Connector (HEV) - (HEADLAMP AND DASH) 47 WAY MODULE-ANTILOCK BRAKES (HEV) - (HEADLAMP AND DASH) 47 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Antilock Brake Module (Headlamp And Dash Side) 38 Way > Page 5519 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module - Description Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Description DESCRIPTION The Antilock Brake Module (ABM) is a microprocessor which handles testing, monitoring and controlling the ABS brake system operation. The ABM is mounted on the top of the hydraulic control unit (HCU). The ABM operates the ABS system and is separate from other vehicle electrical circuits. ABM voltage source is through CKT A111 (fused B+). NOTE: If the ABM needs to be replaced, Perform the ABS verification using a scan tool. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module - Description > Page 5522 Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Operation ABS Unit ABS UNIT SYSTEM SELF-TEST When the ignition switch is turned-on the microprocessor is tested. If an error occurs during the test, a DTC will be set into the memory. However it is possible the DTC will not be stored in memory if the error has occurred in the module were the DTC's are stored. The ABM contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in memory and are accessible with the scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. ABM INPUTS The ABM continuously monitors the speed of the vehicle by monitoring signals generated by the wheel speed sensors. The ABM determines a wheel locking tendency when it recognizes the axle is decelerating too rapidly. The ABM monitors the following inputs to determine when a wheel locking tendency may exists: - Wheel Speed Sensors - Brake Lamp Switch - Brake Fluid Level Sensor (CAN C BUS) - G-Sensor (4X4) ABM OUTPUTS The ABM requests the following outputs for antilock braking and brake warning information from the CCN via CAN C Bus: - ABS Warning Lamp - Brake Warning Lamp ESP Unit ESP UNIT - (ELECTRONIC STABILITY PROGRAM) SYSTEM SELF-TEST When the ignition switch is turned-on the microprocessor is tested. If an error occurs during the test, a DTC will be set into the memory. However it is possible the DTC will not be stored in memory if the error has occurred in the module were the DTC's are stored. The ABM contains a self check program that illuminates the ABS and ESP warning lights when a ABS system fault is detected. If only the ESP light is illuminated ESP system fault is detected. Faults are stored in memory and are accessible with the scan tool. System faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. ABM INPUTS The ABM continuously monitors the speed of the vehicle by monitoring signals generated by the wheel speed sensors. The ABM determines a wheel locking tendency when it recognizes the axle is decelerating too rapidly. The ABM monitors the following inputs to determine when a wheel locking tendency may exists: - Wheel Speed Sensors - Brake Lamp Switch - Brake Fluid Level Sensor (CAN C BUS) - Steering Angle Sensor (SAS) (CAN C BUS) - Dynamic Sensor - ESP Off Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module - Description > Page 5523 - Vacuum Sensor ABM OUTPUTS The ABM requests the following outputs for antilock braking and brake warning information from the CCN via CAN C Bus: - ABS Warning Lamp - Brake Warning Lamp - ESP Warning Lamp - ESP Function Lamp Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal Electronic Brake Control Module: Service and Repair Anti-Lock Brake System Module - Removal REMOVAL CAUTION: When removing ABM from HCU, be sure to completely separate the two components (approximately 38 mm (1.5 in.) before removing ABM. Otherwise, damage to the pressure sensor or Pump Motor connection may result requiring HCU replacement. Do not to touch the sensor terminals on the HCU side or the contact pads on the ABM side as this may result in contamination and issues in the future. NOTE: ABM module can be removed without removing the HCU unit. 1. Remove the left front tire and wheel assembly. 2. Disconnect the electrical connector from the ABM module. 3. Remove the module mounting screws (2). 4. Remove the module from the HCU (1) on ESP vehicles be careful not to damage the pressure sensor or not to touch the sensor terminals on the HCU side or the contact pads on the ABM side when removing the ABM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5526 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System Module - Installation INSTALLATION CAUTION: When removing ABM from HCU, be sure to completely separate the two components (approximately 38 mm (1.5 in.) before removing ABM. Otherwise, damage to the pressure sensor or Pump Motor connection may result requiring HCU replacement. Do not to touch the sensor terminals on the HCU side or the contact pads on the ABM side as this may result in contamination and issues in the future. 1. Position the module on the HCU on ESP vehicles be careful not to damage the pressure sensor or not to touch the sensor terminals on the HCU side or the contact pads on the ABM side when installing the ABM. 2. Install the mounting screws (2) and tighten to 2.5 Nm (22 in. lbs). 3. Connect the scan tool and initialize the ABM by performing the ABS Verification Test See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) Description Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control unit (HCU) - Description DESCRIPTION The HCU consists of a valve body, pump motor, low pressure accumulators, inlet valves, outlet valves and noise attenuators. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) Description > Page 5531 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control unit (HCU) - Operation OPERATION Accumulators in the valve body store extra fluid released from the calipers during ABS mode operation. The pump is used to clear the accumulator of brake fluid and is operated by a DC type motor. The motor is controlled by the ABM. The valves modulate brake pressure during antilock braking and are controlled by the ABM. The HCU provides individual pressure control to each front and rear brake. During antilock braking, the solenoid valves are opened and closed as needed. They are cycled rapidly and continuously to modulate pressure and control wheel slip and deceleration. Brake Traction Control and Electronic Stability Program modulate pressure on each wheel individually without any driver brake input. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without an ABS brake system. During antilock braking, solenoid valve pressure modulation occurs in three stages; pressure increase, pressure hold, and pressure decrease. The valves are all contained in the valve body portion of the HCU. PRESSURE DECREASE The outlet valve is opened and the inlet valve is closed during the pressure decrease cycle. A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the ABM closes the inlet then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the ABM closes the outlet valve and begins a pressure increase or hold cycle as needed. PRESSURE HOLD Both solenoid valves are closed in the pressure hold cycle but only the inlet valve is energized. Fluid apply pressure in the control channel is maintained at a constant rate. The ABM maintains the hold cycle until sensor inputs indicate a pressure change is necessary. PRESSURE INCREASE The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to reapply thew brakes. This cycle controls re-application of fluid apply pressure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control unit (HCU) - Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control unit (HCU) Installation INSTALLATION 1. Reinstall the HCU assembly through the left wheel well. 2. Install HCU assembly on the mounting bracket and Tighten the nuts to 15 Nm (11 ft. lbs.). 3. Install the brake lines (1) to the HCU (4) and tighten to 19 Nm (170 in. lbs.). 4. Install the electrical harness connector (3) to the HCU/ABM assembly (4). 5. Install the chassis lines (1) to the HCU/ABM (2) and tighten to 19 Nm (170 in. lbs.). 6. Install the left front tire. 7. Install negative battery cable to the battery. 8. Remove the brake pedal prop rod. 9. Bleed ABS brake system See: Brake Bleeding/Service and Repair. 10. Connect the scan tool and initialize the ABM by performing the ABS Verification Test See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Control unit (HCU) - Installation > Page 5534 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control unit (HCU) Removal REMOVAL 1. Remove the negative battery cable from the battery. 2. Install a brake pedal prop rod. 3. Siphon the master cylinder. 4. Disconnect the brake lines (1) from the master cylinder to the HCU (4). 5. Disconnect the chassis lines (2) to the HCU (4). 6. Disconnect the electrical harness connector (3). 7. Remove HCU assembly mounting nuts. 8. Raise and support the vehicle. 9. Remove the left front tire. NOTE: Careful not to lose the mounting pins when remove the HCU from the vehicle. 10. Lift the HCU assembly off the mounting bracket. 11. Remove the HCU assembly through the left wheel well. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Diagrams > Dynamics Sensor (ESP) (Instrument Panel) 4 Way Lateral Accelerometer: Diagrams Dynamics Sensor (ESP) (Instrument Panel) 4 Way Connector (ESP) - (INSTRUMENT PANEL) 4 WAY SENSOR-DYNAMICS (ESP) - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Diagrams > Dynamics Sensor (ESP) (Instrument Panel) 4 Way > Page 5540 Lateral Accelerometer: Diagrams Dynamics Sensor (HEV) (Instrument Panel) 6 Way Connector (HEV) - (INSTRUMENT PANEL) 6 WAY SENSOR-DYNAMICS (HEV) - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Description and Operation > Dynamics Sensor - Description Lateral Accelerometer: Description and Operation Dynamics Sensor - Description DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (2). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor (2) must be replaced when necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Description and Operation > Dynamics Sensor - Description > Page 5543 Lateral Accelerometer: Description and Operation G Sensor - Description DESCRIPTION The G-sensor is located only inside the ABS controller 4x4 only. The sensor is not a separate serviceable part from the antilock brake module (ABM). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal Lateral Accelerometer: Service and Repair Dynamics Sensor - Removal REMOVAL 1. Remove the center console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Removal. 2. Disconnect electrical connector (3) from the dynamics sensor (2). 3. Remove the two nuts (1) securing the sensor to the floor. 4. Remove the sensor (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 5546 Lateral Accelerometer: Service and Repair Dynamics Sensor - Installation INSTALLATION 1. Install the dynamics sensor (2) on the studs (4) to the vehicle. NOTE: Make sure the electrical connector is facing toward the rear of the vehicle. 2. Connect the electrical connector (3) to the sensor (2). 3. Install the two retaining nuts (1) and tighten to 6 Nm (53 in. lbs.). 4. Install the floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Installation. 5. Perform the ABS verification test with the scan tool. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 5550 Steering Angle Sensor: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SENSOR-STEERING ANGLE - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 5551 Steering Angle Sensor: Description and Operation DESCRIPTION NOTE: Steering angle sensor is part of the airbag clockspring and is not serviced separately from the clockspring. The steering angle sensor is used to measure the driver intended path in the ESP system. Based on the deviation between steering wheel input and the Yaw Rate signal from the dynamic sensor, ESP can be activated. The SAS should be mounted correctly to ensure that the system functions properly and there are not inadvertent activations. Any replacement of the steering angle sensor requires that the ABS verification test be performed. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Service and Repair > Removal Steering Angle Sensor: Service and Repair Removal REMOVAL NOTE: Steering angle sensor is part of the airbag clockspring and is not serviced separately from the clockspring. 1. For removal of the steering angle sensor See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement/Clockspring - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Steering Angle Sensor, Traction Control > Component Information > Service and Repair > Removal > Page 5554 Steering Angle Sensor: Service and Repair Installation INSTALLATION NOTE: Steering angle sensor is part of the airbag clockspring and is not serviced separately from the clockspring. 1. For installation of the steering angle sensor See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement/Clockspring - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Description and Operation > ESP With BAS Indicator - Description Traction Control Indicator Lamp: Description and Operation ESP With BAS Indicator - Description DESCRIPTION An Electronic Stability Program/Brake Assist System (ESP/BAS) indicator is standard equipment on all instrument clusters. This indicator is located in the center of the speedometer, in the area below and to the left of the speedometer needle hub. The ESP/BAS indicator consists of a stencil-like cutout of the text ESP BAS in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ESP/BAS indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Description and Operation > ESP With BAS Indicator - Description > Page 5559 Traction Control Indicator Lamp: Description and Operation ESP With BAS Indicator - Operation OPERATION The ESP/BAS indicator gives an indication to the vehicle operator when a problem has been detected in the Electronic Stability Program (ESP)/Brake Assist System (BAS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) and the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The ESP/BAS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ESP/BAS indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the on position the ESP/BAS indicator illuminates for about four seconds as a bulb test. - ESP/BAS Indicator Lamp-On Message - Each time the cluster receives an electronic ESP/BAS indicator lamp-on message from the CAB or the FCM, the ESP/BAS indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB or FCM, or until the ignition switch is turned to the off position, whichever occurs first. self Test - Each time the cluster is put through the self test, the ESP/BAS indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CAB and FCM continually monitor the ESP/BAS system circuits and sensors to decide whether the system is in good operating condition and the proper outputs to the components of the system. The CAB or FCM then sends the proper lamp-ON or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). Use a diagnostic scan tool for proper diagnosis of the ESP/BAS system, the CAB, the FCM, the CCN, the CAN data bus or the electronic communication related to ESP/BAS indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Description and Operation > ESP With BAS Indicator - Description > Page 5560 Traction Control Indicator Lamp: Description and Operation Traction Control Indicator - Description DESCRIPTION An Electronic Stability Program/Brake Assist System (ESP/BAS)/Traction Control System (TCS) traction control indicator is standard equipment on all instrument clusters. This indicator is located in the center of the speedometer, in the area above and to the right of the speedometer needle hub. The traction control indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Stability - Anti-Spin in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The traction control indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Indicator Lamp > Component Information > Description and Operation > ESP With BAS Indicator - Description > Page 5561 Traction Control Indicator Lamp: Description and Operation Traction Control Indicator - Operation OPERATION The traction control indicator gives an indication to the vehicle operator when the Electronic Stability Program (ESP)/Brake Assist System (BAS)/Traction Control System (TCS) has been activated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus. The traction control indicator is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator is always off when the ignition switch is in any position except ON or START. The indicator only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the traction control indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the traction control indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - Traction Control Indicator Lamp-On Message - Each time the cluster receives an electronic traction control indicator lamp-on message from the CAB indicating that the ESP/BAS/TCS has been activated, the traction control indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the traction control indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CAB continually monitors the status of the inputs to the ESP/BAS/TCS systems to determine the proper outputs to the components of the Antilock Brake System (ABS). The CAB then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the traction control indicator or the instrument cluster circuitry that controls the indicator, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the ESP/BAS/TCS, the CAB, the CCN, the CAN data bus or the electronic communication related to traction control indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Locations > Page 5565 Traction Control Switch: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SWITCH-TRACTION CONTROL - (INSTRUMENT PANEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations > Page 5569 Vacuum Brake Booster Diaphragm Position Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 3 WAY SENSOR-BOOSTER TRAVEL (HEV) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Description DESCRIPTION The travel sensor (7) is mounted on power brake booster (1) below and to the left of the master cylinder, and has one electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description > Page 5572 Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Operation OPERATION The travel sensor is a three-wire potentiometer that varies the voltage output as the position of the booster diaphragm changes. The RBS module uses the position information to determine the amount of booster movement and hydraulic brake application. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor - Removal REMOVAL 1. Disconnect the electrical connector (2) from the travel sensor (1). NOTE: The retainer clip does not need to be removed, only pushed up slightly to disengage the tabs on the sensor. 2. Using a small screw driver (4) or another suitable tool, push up on the retainer clip (2) and pull the travel sensor (3) from the power brake booster (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal > Page 5575 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor Installation INSTALLATION NOTE: When replacing the travel sensor, the Anti-Lock Brake Module (ABM) must be initialized using the scan tool. To initialize the ABM perform the ABS VERIFICATION TEST - HEV. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test . NOTE: Verify that the surface is clean, the old O-ring is removed, and the new O-ring is properly positioned on the sensor. 1. With a slight twisting motion, push the travel sensor (3) into the power brake booster (1). There should be a slight snapping sound as the retainer clip (3) seats into position. 2. Verify that the travel sensor retainer clip (3) snapped into place. 3. Connect the electrical connector (2) to the travel sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 5580 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 5581 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 5582 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT FRONT - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way > Page 5585 Wheel Speed Sensor: Diagrams Left Rear Wheel Speed Sensor (Chassis) 2 Way Connector - (CHASSIS) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT REAR - (CHASSIS) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way > Page 5586 Wheel Speed Sensor: Diagrams Right Front Wheel Speed Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT FRONT - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way > Page 5587 Wheel Speed Sensor: Diagrams Right Rear Wheel Speed Sensor (Chassis) 2 Way Connector - (CHASSIS) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT REAR - (CHASSIS) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Diagrams > Page 5588 Wheel Speed Sensor: Description and Operation OPERATION The sensors convert wheel speed into a digital signal. The ABM sends 12 volts to the sensors. The sensor has an internal hall sensor that alters the voltage and amperage of the signal circuit. This voltage and amperage is changed by magnetic induction when the toothed tone wheel passes the wheel speed sensor. This digital signal is sent to the ABM. The ABM measures the voltage and amperage of the digital signal for each wheel. The signal strength is affected by the distance between the Sensor and the tone ring. If the "Air Gap" between the WSS and the tone ring/wheel is too large, the WSS signal can drop out at low speed, (below 40 mph) and can cause an ABS activation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Removal Front REMOVAL 1. Remove the front rotor See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 2. Remove the wheel speed sensor mounting bolt (1) from the hub (3). 3. Remove the wheel speed sensor (2) from the hub (3). 4. Remove the wiring from the clips and disconnect the electrical connector. Rear REMOVAL 1. Raise the vehicle on a hoist. 2. Disconnect the wheel speed sensor electrical connector (3). 3. Remove the mounting bolt (1) from the sensor (4). 4. Remove the sensor (4) from the brake caliper adapter (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5591 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Installation Front INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor (2) to the hub (3). 3. Install the wheel speed sensor mounting bolt (1) to the hub (3). Tighten the bolt to 21 Nm (190 in. lbs.). 4. Install the front rotor and brake caliper assembly See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. Rear INSTALLATION 1. Insert the wheel speed sensor (4) in the brake caliper adapter (2). 2. Install the sensor mounting bolt (1) and tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical wiring connector (3) to the sensor (4). 4. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Diagrams > Dynamics Sensor (ESP) (Instrument Panel) 4 Way Yaw Rate Sensor: Diagrams Dynamics Sensor (ESP) (Instrument Panel) 4 Way Connector (ESP) - (INSTRUMENT PANEL) 4 WAY SENSOR-DYNAMICS (ESP) - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Diagrams > Dynamics Sensor (ESP) (Instrument Panel) 4 Way > Page 5597 Yaw Rate Sensor: Diagrams Dynamics Sensor (HEV) (Instrument Panel) 6 Way Connector (HEV) - (INSTRUMENT PANEL) 6 WAY SENSOR-DYNAMICS (HEV) - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Description and Operation > Dynamics Sensor - Description Yaw Rate Sensor: Description and Operation Dynamics Sensor - Description DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (2). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor (2) must be replaced when necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Description and Operation > Dynamics Sensor - Description > Page 5600 Yaw Rate Sensor: Description and Operation G Sensor - Description DESCRIPTION The G-sensor is located only inside the ABS controller 4x4 only. The sensor is not a separate serviceable part from the antilock brake module (ABM). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal Yaw Rate Sensor: Service and Repair Dynamics Sensor - Removal REMOVAL 1. Remove the center console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Removal. 2. Disconnect electrical connector (3) from the dynamics sensor (2). 3. Remove the two nuts (1) securing the sensor to the floor. 4. Remove the sensor (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 5603 Yaw Rate Sensor: Service and Repair Dynamics Sensor - Installation INSTALLATION 1. Install the dynamics sensor (2) on the studs (4) to the vehicle. NOTE: Make sure the electrical connector is facing toward the rear of the vehicle. 2. Connect the electrical connector (3) to the sensor (2). 3. Install the two retaining nuts (1) and tighten to 6 Nm (53 in. lbs.). 4. Install the floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Installation. 5. Perform the ABS verification test with the scan tool. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Brake Bleeding Brake Bleeding: Service and Repair Manual Brake Bleeding MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers were overhauled, open all caliper bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose (1) to bleed screw and insert opposite end in glass container (2) partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear (3) Right front (4) Left front. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down, hold the pedal down while closing the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. 5. Before moving the vehicle verify the pedal is firm and not mushy. 6. Top off the brake fluid and install the reservoir cap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Brake Bleeding > Page 5608 Brake Bleeding: Service and Repair Pressure Brake Bleeding PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Brake Bleeding > Page 5609 Brake Bleeding: Service and Repair Antilock Brake System Bleeding ABS BRAKE BLEEDING ABS system bleeding requires conventional bleeding methods plus use of the scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. See: OR See: . 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. See: . 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Brake and/or Accelerator Pedals - Description Brake Pedal Assy: Description and Operation Brake and/or Accelerator Pedals - Description DESCRIPTION STANDARD PEDALS NOTE: The brake pedal is serviced as a complete assembly including the bracket. A suspended-type brake pedal (5) is used. The pedal is attached to the pedal support bracket (4) with a pivot shaft pin (2), bushings (3) and clips (1). If the bushings (3) become dry a spray lubricant can be used to eliminate noises. The booster push rod is attached to the pedal with a clip. The pedal (5), bushings (3), pivot pin (2) and support bracket (4) are not serviceable components. ADJUSTABLE PEDALS - WITHOUT 5.7L HEV NOTE: The non HEV adjustable pedal assembly can be serviced in 5 sub components as listed below. NOTE: When replacing the components both pedal assemblies must be in the fully down position toward the floor for proper adjustment. Pedals can be moved manually by rotating the cable on the component not being replaced. New components come in the correct position until activated. The adjustable brake pedal assembly is similar to the standard brake pedal assembly with additional components necessary for pedal adjustment. Sub components may be replaced separately. Replaceable sub components are as follows: - Accelerator pedal (5) - Bracket housing (2) - Brake pedal assembly (1) - Drive cable (between motor and brake pedal) (3) - Motor (4) ADJUSTABLE PEDALS - 5.7L HEV Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Brake and/or Accelerator Pedals - Description > Page 5614 NOTE: The 5.7L HEV brake pedal assembly is serviced as a complete assembly including the bracket. The 5.7L HEV brake pedal assembly is similar to the non HEV brake pedal assembly with additional components necessary for the overall operation of the HEV systems. The components are calibrated together and cannot be interchanged or replaced separately. HEV specific components (not serviced separately) are listed below: - Brake pedal angle sensor (1) - Brake pedal simulator cut off (3) - Brake pedal simulator (4) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Description and Operation > Brake and/or Accelerator Pedals - Description > Page 5615 Brake Pedal Assy: Description and Operation Brake and/or Accelerator Pedals - Operation OPERATION WITHOUT 5.7L HEV The brake pedal is attached to the booster push rod. When the pedal is depressed, the primary booster push rod will move the booster secondary rod. The booster secondary rod will then depress the master cylinder piston, and the brakes will apply. WITH 5.7L HEV NOTE: The brake pedal assembly and it's components are serviced as an assembly only. The master cylinder may be replaced separately or as a unit with the active brake booster. The brake pedal is attached to the booster primary push rod which is not directly connected to the booster secondary push rod. Instead, there is a pedal simulator assembly (2) which consists of a pedal simulator cut off solenoid (3) and a pedal simulator (4 ) which creates normal pedal feel during braking maneuvers. When there is a brake pedal application the pedal simulator creates pressure against the pedal while the transmission motors actually slow the vehicle, and in turn charge the 300V batteries. This is called regenerative braking. When the brake pedal is depressed with a specific predetermined force/rate the booster will assist with normal brakes without the booster push rod connecting. Under an emergency stop or a system fault the pedal simulator cut off solenoid will deactivate the simulator and allow the booster push rod to connect directly to the pedal. Under this condition the brake pedal will have slightly longer travel to allow direct contact with the booster push rod. For more information on regenerative braking See: Antilock Brakes / Traction Control Systems/Description and Operation/Brakes - Operation. Below is a brief explanation of the components of the brake pedal assembly that is unique to the 5.7L HEV: - BRAKE PEDAL ASSEMBLYThe brake pedal assembly consists of the pedal bracket and all components as described below. - BRAKE PEDAL ANGLE (BPA) SENSORThe BPA sensor has two signal circuits to the ABS module to accurately monitor the brake demand. One signal circuit increases voltage and the other signal circuit decreases voltage when the brakes are applied. - BRAKE PEDAL SIMULATORThe brake pedal simulator consists of linkage that compresses a coil spring and rubber bumper (internally) to absorb the brake pedal input without mechanically pressing the brake master cylinder push rod. This process preserves brake pedal feel and allows regenerative braking. - BRAKE PEDAL SIMULATOR CUT OFF SOLENOID (WITH PRESSURE SENSOR)The brake pedal simulator cut off solenoid is used to engage or disengage the pedal feel simulator and is controlled by the ABS module. Internal to the cut off solenoid are two small hydraulic chambers with spring loaded diaphragms that have an electronic solenoid in the fluid passage between the chambers that closes when activated. When energized the brake pedal feel simulator operates and when not energized the brake pedal feel simulator is deactivated. If voltage is lost to the cut off solenoid it defaults to deactivated and normal vacuum assisted braking remains. If the brake pedal feel simulator is deactivated the brake pedal travel will increase. The pressure sensor which is part of the brake pedal simulator cut off solenoid has a variable signal to the ABS module to determine how hard the brake pedal is being depressed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal Brake Pedal Assy: Service and Repair Brake and/or Accelerator Pedals - Removal WITH 5.7L HEV WARNING: Before servicing the steering column the air bag system must be disarmed. Refer to electrical restraint system for service procedures. Failure to do so may result in accidental deployment of the airbag and possible personal injury. NOTE: The Brake Pedal Assembly is serviced as a complete assembly including the bracket. 1. Place the front wheels in the straight ahead position. 2. Remove the steering column, See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column Removal 3. Remove the brake lamp switch and discard it.Do not reuse the stop lamp switch.See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Removal. 4. Remove the main I/P harness connector (1) bracket bolts (2) from the brake pedal assembly bracket. 5. Disconnect the steering column harness from the retainer (1), the four brake pedal assembly component connectors (2-5), and the brake pedal angle sensor connector (not shown) located at the top left outside area of the brake pedal assembly bracket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal > Page 5618 6. Remove the brake booster rod to brake pedal retainer clip (3) and spacer (2). Discard the retainer clip (3). 7. NOTE: Verify the positioning of the brake booster rod (1) for proper installation. The pad (4) must be positioned so the spacer (2) can contact the pad (4) when the brakes are applied. Reposition the brake booster rod (1) away from the brake pedal shaft. 8. Remove the brake pedal assembly rear mounting bolts (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal > Page 5619 9. Loosen the brake pedal assembly forward mounting bolt (2) (located in front of the brake pedal feel simulator) for access to slide the assembly from the instrument panel. 10. Remove the brake booster nuts (1) and discard. 11. Remove the brake pedal assembly to cowl nut (2). 12. Remove the brake pedal assembly from the vehicle by sliding assembly rearward off the forward mounting bolt. 13. Remove and transfer any necessary components. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal > Page 5620 Brake Pedal Assy: Service and Repair Brake and/or Accelerator Pedals - Installation WITH 5.7L HEV NOTE: When replacing the brake pedal assembly, the Anti-Lock Brake Module (ABM) must be initialized using the scan tool. To initialize the ABM perform the ABS VERIFICATION TEST - HEV, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test . 1. With the brake pedal assembly forward mounting bolt (2 ) installed 1/2 way, guide the brake pedal assembly onto the slot (3) and slide the brake pedal assembly forward over the bolt (2) and the brake booster studs. Do not tighten at this time. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal > Page 5621 2. Install the brake pedal assembly rear mounting bolts (1). Do not tighten at this time. 3. Install the three new booster attaching nuts (1). Tighten the nuts to 31 Nm (275 in. lbs.). 4. Install the brake pedal assembly to cowl nut (2). Tighten the nut to 31 Nm (275 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal > Page 5622 5. Tighten the brake pedal assembly rear mounting bolts (1) to 13.5 Nm (120 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal > Page 5623 6. Tighten the brake pedal assembly forward mounting bolt (2) to 27 Nm (240 in. lbs.). 7. NOTE: Verify the positioning of the brake booster rod (1) before installation. The pad (4) must be positioned so the spacer (2) can contact the pad (4) when the brakes are applied. Place the brake booster rod (1) over the brake pedal shaft. 8. Install the spacer (2) and a new brake pedal retainer clip (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Brake and/or Accelerator Pedals - Removal > Page 5624 9. Connect the steering column harness to the retainer (1), the four brake pedal assembly component connectors (2-5), and the brake pedal angle sensor connector (not shown) located at the top left outside area of the brake pedal assembly. 10. Install the main I/P harness connector (1) bracket bolts (2) to the brake pedal assembly. Tighten the bolts to 28 Nm (250 in. lbs.). CAUTION: Do not reuse the original stop lamp switch. Anytime a switch has been removed or its position compromised, a new switch must be installed and adjusted. Do not attempt to readjust the switch. 11. Install and adjust a NEW stop lamp switch. See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Installation 12. Install the steering column, See: Steering and Suspension/Steering/Steering Column/Service and Repair/Steering Column - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Brake/Parking Brake Indicator - Description Brake Warning Indicator: Description and Operation Brake/Parking Brake Indicator - Description DESCRIPTION A brake indicator is standard equipment on all instrument clusters. This indicator is located in the center of the speedometer, in the area below and right of the speedometer needle hub. The brake indicator consists of a stencil-like cutout of the word BRAKE (all clusters with a miles-per-hour primary speedometer scale), or the International Control and Display Symbol icon for Brake Failure (all clusters with a kilometers-per-hour primary scale) in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Brake/Parking Brake Indicator - Description > Page 5629 Brake Warning Indicator: Description and Operation Brake/Parking Brake Indicator - Operation OPERATION The brake indicator gives an indication to the vehicle operator when the parking brake is applied, when there are certain brake hydraulic system malfunctions as indicated by a low brake hydraulic fluid level condition, or when the brake fluid level switch is disconnected. The brake indicator can also give an indication when certain faults are detected in the Antilock Brake System (ABS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus, and a hard wired input from the park brake switch. The brake indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the brake indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the brake indicator illuminates for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - Brake Indicator Lamp-On Message - Each time the cluster receives an electronic brake indicator lamp-on message from the CAB, the brake indicator illuminates. The CAB may also send lamp-on messages as feedback during ABS diagnostic procedures. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Park Brake Switch Input - Each time the cluster detects ground on the park brake switch sense circuit (park brake switch closed = park brake applied or not fully released) while the ignition switch is in the ON position, the brake indicator flashes on and off. The indicator continues to flash until the park brake switch sense input to the cluster is an open circuit (park brake switch open = park brake fully released), or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the instrument cluster is put through the self test, the brake indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hardwired ground input to the instrument cluster circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CAB continually monitors the ABS system circuits and sensors, including the brake fluid level switch on the brake master cylinder reservoir, to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction or that the ABS system has become ineffective. The CAB stores a Diagnostic Trouble Code (DTC) for any malfunction it detects. For further diagnosis of the brake indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use conventional diagnostic tools and procedures for the hardwired park brake switch input to the instrument cluster. Refer to the appropriate wiring information. Use a diagnostic scan tool for proper diagnosis of the brake fluid level switch, the ABS, the CAB, the CCN, the CAN data bus or the electronic communication related to brake indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Brake/Parking Brake Indicator - Description > Page 5630 Brake Warning Indicator: Description and Operation Regenerative Brake Indicator - Description DESCRIPTION A Regenerative Brake System (RBS) indicator is only found in the instrument clusters of vehicles equipped with the optional Hybrid Electrical Vehicle (HEV) system. This indicator is located below the minor gauge set on the left side of the cluster. The RBS indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Failure of Anti-lock Braking System in the opaque layer of the instrument cluster overlay, but with the letter R replacing the letter A in the ABS acronym. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The RBS indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Brake/Parking Brake Indicator - Description > Page 5631 Brake Warning Indicator: Description and Operation Regenerative Brake Indicator - Operation OPERATION The Regenerative Brake System (RBS) indicator gives an indication to the vehicle operator when the RBS system, or a circuit or component of the system is ineffective. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Regenerative Brake Controller (RBC) (also known as the Controller Antilock Brake/CAB) over the Controller Area Network (CAN) data bus. The RBS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the RBS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turns to the on position the RBS indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the RBC. - RBS Indicator Lamp-On Message - Each time the cluster receives an electronic RBS indicator lamp-on message from the RBC, the RBS indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the RBC, or until the ignition switch turns to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the RBC for five consecutive message cycles, the RBS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the RBC, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the instrument cluster is put through the self test, the RBS indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - RBS Diagnostic Test - The RBS indicator is blinked on and off by lamp-on and lamp-off messages from the RBC during the performance of the RBS diagnostic tests. The RBC continually monitors the RBS circuits and sensors to decide whether the system is in good operating condition. The RBC then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the RBC sends a lamp-on message after the bulb test, it indicates that the RBC has detected a system malfunction or that the RBS system has become ineffective. The RBC stores a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the RBS indicator fails to light due to an open or short in the cluster RBS indicator circuit, the cluster sends a message notifying the RBC of the condition, then the instrument cluster and the RBC will each store a DTC. Use a diagnostic scan tool for proper diagnosis of the regenerative brake system, the RBC, the CCN, the CAN data bus or the electronic communication related to RBS indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation > Page 5632 Brake Warning Indicator: Testing and Inspection BRAKE INDICATOR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. The hardwired park brake switch input to the instrument cluster, also known as the Cab Compartment Node, (CCN) may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire harness and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CCN, the Controller Antilock Brake (CAB), the Controller Area Network (CAN) data bus or the electronic message inputs also used by the CCN to provide brake indicator operation. The most reliable, efficient and accurate means to diagnose the CCN, the CAB, the CAN data bus or the electronic communication related to brake indicator operation, requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Disc Brake Caliper - Description Brake Caliper: Description and Operation Disc Brake Caliper - Description DESCRIPTION The calipers are a single piston type in the rear and dual piston type in the front. The calipers are free to slide laterally, this allows continuous compensation for lining wear. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Disc Brake Caliper - Description > Page 5638 Brake Caliper: Description and Operation Disc Brake Caliper - Operation OPERATION When the brakes are applied fluid pressure is exerted against the caliper piston (2). The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Fluid pressure applied to the piston is transmitted directly to the inboard brake pad (5). This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake pad lining (6) into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied, friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake pads do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal (4) controls the amount of piston (2) extension needed to compensate for normal lining wear. During brake application, the seal is deflected outward by fluid pressure and piston movement(6). When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston (3). The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake pad. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures Brake Caliper: Procedures Disc Brake Caliper - Cleaning CLEANING Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air. CAUTION: Do not use gasoline, kerosene, paint thinner, or similar solvents. These products may leave a residue that could damage the piston and seal. Disc Brake Caliper - Inspection INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. The bore can be lightly polished with a brake hone (3) to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5641 Brake Caliper: Removal and Replacement Disc Brake Caliper Adapter Mounting Bracket - Removal REMOVAL 1. Remove wheel and tire assembly. 2. Remove the disc brake caliper (3) See: Disc Brake Caliper - Removal. 3. Remove the caliper adapter (2) See: Disc Brake Caliper Adapter - Removal. 4. Remove the rotor (1) See: Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 5. Remove the axle shaft (1) See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair/Rear Axle - 9 1/4/Removal. 6. Remove the park brake shoes (1) See: Parking Brake System/Parking Brake Shoe/Service and Repair/Removal and Replacement/Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5642 7. Remove the parking brake cable (2) from the brake lever (1). 8. Remove the bolts (2) attaching the support plate to the axle and remove the support plate (1). 9. Remove the caliper adapter mount (1) from the axle housing (2). Disc Brake Caliper Adapter Mounting Bracket - Installation INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5643 1. Install the caliper adapter mount (1) on the axle housing (2). 2. Install support plate (1) on axle flange. Tighten attaching bolts (2) to 64 Nm (47 ft. lbs.). 3. Install parking brake cable (2) in the brake lever (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5644 4. Install the park brake shoes (1) See: Parking Brake System/Parking Brake Shoe/Service and Repair/Removal and Replacement/Installation. 5. Install axle shaft (1), See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair/Rear Axle - 9 1/4/Installation. 6. Adjust brake shoes to drum (2) with brake gauge (1), See: Parking Brake System/Parking Brake Shoe/Adjustments. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5645 7. Install the rotor (1) See: Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. 8. Install the caliper adapter (2) See: Disc Brake Caliper Adapter - Installation. 9. Install the caliper (3) See: Disc Brake Caliper - Installation. 10. Install wheel and tire assembly. Front FRONT CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support the vehicle. 3. Remove the tire and wheel assembly. 4. Compress the disc brake caliper (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5646 5. Remove the banjo bolt (1) and discard the copper washers (4). 6. Remove the caliper slide pin bolts. 7. Remove the disc brake caliper from the caliper adapter (3). Rear REAR 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support vehicle. 3. Remove the wheel and tire assembly (6). 4. Drain small amount of fluid from master cylinder brake reservoir with suction gun. 5. Remove the brake hose banjo bolt (5) if replacing caliper (4). 6. Remove the caliper mounting slide pin bolts (2). 7. Remove the caliper (4) from vehicle. Front FRONT Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5647 NOTE: Install new copper washers on the banjo bolt when installing 1. Install the disc brake caliper (2) to the brake caliper adapter (3). CAUTION: Verify brake hose (3) is not twisted or kinked before tightening fitting bolt. 2. Install the banjo bolt (1) with new copper washers (4) to the caliper (2). Tighten to 18 Nm (155 in. lbs.) 3. Install the caliper slide pin bolts. Tighten to 32 Nm (24 ft. lbs.) 4. Remove the prop rod from the vehicle. 5. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a complete system bleed procedure must be performed.See: Brake Bleeding/Service and Repair. 6. Install the tire and wheel assembly, See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. 7. Lower the vehicle. Rear REAR 1. Install the caliper (4) to the caliper adapter (7). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5648 2. Coat the caliper mounting slide pin bolts (2) with silicone grease. Then install and tighten the bolts to 15 Nm (11 ft. lbs.). 3. Install the brake hose banjo bolt (5) and new copper seal washers if caliper was removed. CAUTION: Verify that the brake hose is not twisted or kinked before tightening the fitting bolt. 4. Install the brake hose (3) to the caliper (4) using a banjo washer, and tighten bolt to 18 Nm (155 in. lbs.). 5. Remove the prop rod from the vehicle. 6. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair, then a complete system bleed procedure must be performed.See: Brake Bleeding/Service and Repair. 7. Install the wheel and tire assemblies (6). See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. 8. Remove the supports and lower the vehicle. 9. Verify a firm pedal before moving the vehicle. Front FRONT 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the disc brake caliper (1) See: Disc Brake Caliper - Removal. 4. Remove the bolts securing the caliper adapter (2) to the steering knuckle 5. Remove the caliper adapter. Rear REAR 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Drain a small amount of fluid from master cylinder brake reservoir with a clean suction gun. 4. Bottom the caliper pistons into the caliper by prying the caliper over. 5. Remove the caliper mounting bolts. 6. Remove the disc brake caliper from the mount. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5649 CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 7. Remove the inboard and outboard brake pads (1). 8. Remove the anti-rattle clips (2). 9. Remove the caliper adapter mounting bolts (4). Front FRONT 1. Install the caliper adapter (1) to the steering knuckle. 2. Install the caliper adapter mounting bolts (2) and tighten to 176 Nm (130 ft.lbs.). 3. Install the disc brake caliper (1)See: Disc Brake Caliper Installation. 4. Install the tire and wheel assembly See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. 5. Remove the support and lower the vehicle. Rear REAR 1. Install the caliper adapter mounting bolts (4). Tighten the mounting bolts to 135 Nm (100 ft.lbs). 2. Install the anti-rattle clips (2). 3. Install the inboard and outboard pads (1). 4. Install the caliper mounting bolts. 5. Install the tire and wheel assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5650 Brake Caliper: Overhaul Disc Brake Caliper - Disassembly DISASSEMBLY 1. Drain the brake fluid from caliper. 2. C-clamp (2) a block of wood (1) over one piston. 3. Take another piece of wood and pad it with one-inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: Never attempt to catch the piston as it leaves the bore. This could result in personal injury. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5651 8. Remove piston dust boots (2) with a suitable pry tool. CAUTION: Do not scratch piston bore while removing the seals. 9. Remove piston seals (3) from caliper (1). 10. Push caliper mounting bolt bushings (3) out of the boot seals (2) and remove the boot seals from the caliper (1). 11. Remove caliper bleed screw. Disc Brake Caliper - Assembly ASSEMBLY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5652 CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. NOTE: Verify seal is fully seated and not twisted. 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. 2. Install new piston seals (3) into caliper bores (2). 3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston (3). 4. Stretch boot (2) rearward to straighten boot folds, then move boot forward until folds snap into place. 5. Install piston (3) into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle. 6. Seat dust boot in caliper (2) with Handle C-4171 (1) and Installer (3): - 54 mm caliper: Installer C-3716-A 7. Install the second piston and dust boot. CAUTION: Use of alternative grease may cause damage to the boots seals. 8. Lubricate caliper mounting bolt bushings, boot seals and bores with Mopar brake grease or Dow Corning(R) 807 grease only. 9. Install the boot seals into the caliper seal bores and center the seals in the bores. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5653 10. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing grooves at either end of the bushing. 11. Install caliper bleed screw. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications BRAKE PAD THICKNESS Measure brake pad minimum thickness (1). Brake pads must be replaced when usable material on a brake pad lining (2) measured at its thinnest point measures one millimeter (0.04 inches) or less. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures Brake Pad: Procedures INSPECTION Visually inspect brake pads for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indicators (if equipped) on the pads and the brake rotors. If a visual inspection does not adequately determine the condition of the lining, a physical check will be necessary. To check the amount of lining wear, remove the disc brake pads from the vehicle. Measure brake pad minimum thickness (1). Brake pads must be replaced when usable material on a brake pad lining (2) measured at its thinnest point measures one millimeter (0.04 inches) or less. If a brake pad fails inspection, replace both disc brake pads (inboard and outboard) at each caliper. It is also necessary to replace the pads on the opposite side of the vehicle as well as the pads failing inspection to maintain proper braking characteristics. If the brake pad assemblies do not require replacement, be sure to reinstall the brake pads in the original position they were removed from. NOTE: It is important to inspect both front and rear brake pads during the same inspection. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5659 Brake Pad: Removal and Replacement Brake Pads - Removal REMOVAL 1. Raise and support vehicle. 2. Remove the wheel and tire assemblies. 3. Compress the caliper. 4. Remove the caliper, See: Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper - Removal. 5. Remove the caliper by tilting the top up and off the caliper adapter. NOTE: Do not allow brake hose to support caliper assembly. 6. Support and hang the caliper. 7. Remove the inboard brake shoe from the caliper adapter. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5660 8. Remove the outboard brake shoe from the caliper adapter. NOTE: Anti-rattle springs are not interchangeable. 9. Remove the top anti-rattle springs from the caliper adapter. 10. Remove the bottom anti-rattle springs from the caliper adapter. Brake Pads - Installation INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5661 1. Bottom pistons in caliper bore with C-clamp. Place an old brake shoe between a C-clamp and caliper piston. 2. Clean caliper mounting adapter and anti-rattle springs. 3. Lubricate anti-rattle springs with Mopar brake grease. NOTE: Anti-rattle springs are not interchangeable. 4. Install the bottom anti-rattle springs. 5. Install the top anti-rattle springs. 6. Install inboard brake shoe in adapter. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Procedures > Page 5662 7. Install outboard brake shoe in adapter. 8. Tilt the top of the caliper over rotor and under adapter. Then push the bottom of the caliper down onto the adapter. 9. Install caliper, See: Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper - Installation. 10. Install wheel and tire assemblies and lower vehicle, See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. 11. If equipped with a 5.7L HEV, disconnect the 12 volt battery system ground isolation connector (1). 12. Apply brakes several times to seat caliper pistons and brake shoes and obtain firm pedal. 13. Top off master cylinder fluid level. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications Brake Rotor/Disc: Specifications SPECIFICATIONS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5666 Brake Rotor/Disc: Testing and Inspection DISC BRAKE ROTOR The rotor braking surfaces should not be refinished unless necessary. Light surface rust and scale can be removed with a lathe equipped with dual sanding discs. The rotor surfaces can be restored by machining with a disc brake lathe if surface scoring and wear are light. Replace the rotor for the following conditions: - Severely Scored - Tapered - Hard Spots - Cracked - Below Minimum Thickness ROTOR MINIMUM THICKNESS Measure rotor thickness at the center of the brake shoe contact surface. Replace the rotor if below minimum thickness, or if machining would reduce thickness below the allowable minimum. Rotor minimum thickness is usually specified on the rotor hub. The specification is either stamped or cast into the hub surface. ROTOR RUNOUT Check rotor lateral runout with dial indicator C-3339A. Excessive lateral runout will cause brake pedal pulsation and rapid, uneven wear of the brake shoes. Position the dial indicator plunger approximately 25.4 mm (1 in.) inward from the rotor edge. NOTE: Be sure wheel bearing has zero end play before checking rotor runout. Maximum allowable rotor runout is 0.131 mm (0.002 in.). ROTOR THICKNESS VARIATION Variations in rotor thickness will cause pedal pulsation, noise and shudder. Measure rotor thickness at 6 to 12 points around the rotor face. Position the micrometer approximately 25.4 mm (1 in.) from the rotor outer circumference for each measurement. Thickness should not vary by more than 0.015 mm (0.0059 in.) from point-to-point on the rotor. Machine or replace the rotor if necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Page 5667 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures Brake Rotor/Disc: Procedures Brake Rotor Machining DISC BRAKE ROTOR MACHINING NOTE: A hub mounted on-vehicle lathe is highly recommended. This type of lathe trues the rotor to the vehicles hub/bearing. The disc brake rotor can be machined if scored or worn. The on-vehicle lathe must machine both sides of the rotor simultaneously with dual cutter heads. The rotor mounting surface must be clean before placing on the on-vehicle lathe. Equipment capable of machining only one side at a time may produce a tapered rotor This type of rotor machining is not recommended. NOTE: Proper wheel torque is also critical to help prevent any warping of the disc brake rotor. CAUTION: Brake rotors that do not meet minimum thickness specifications before or after machining must be replaced. Brake Drum in Hat Rotor Machining BRAKE DRUM IN HAT ROTOR MACHINING The brake drum in hat rotor can be machined on a drum lathe when necessary. Initial machining cuts should be limited to 0.12 - 0.20 mm (0.005 - 0.008 in.) at a time as heavier feed rates can produce taper and surface variation. Final finish cuts of 0.025 to 0.038 mm (0.001 to 0.0015 in.) are recommended and will generally provide the best surface finish. Be sure the drum in hat rotor is securely mounted in the lathe before machining operations. A damper strap should always be used around the drum to reduce vibration and avoid chatter marks. The maximum allowable diameter of the drum braking surface is stamped or cast into the drum in hat rotor. CAUTION: Replace the drum in hat rotor if machining will cause the drum to exceed the maximum allowable diameter. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5670 Brake Rotor/Disc: Removal and Replacement Front FRONT 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. NOTE: Do not allow brake hose to support caliper adapter assembly. 3. Remove the caliper (2) from the steering knuckle (1), See: Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper Removal and remove caliper adapter assembly. 4. Remove the rotor (1) from the hub/bearing wheel studs (2). Rear REAR Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5671 1. Raise and support the vehicle 2. Remove the tire and wheel assembly. 3. Remove the disc brake caliper See: Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper - Removal. 4. Remove the caliper adapter bolts.See: Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper Adapter - Removal 5. Remove the disc brake caliper adapter (2). 6. Remove the retaining clips and rotor assembly (1). Front FRONT 1. On models with all-wheel antilock system (ABS), check condition of tone wheel on hub/bearing. If teeth on wheel are damaged, hub/bearing assembly will have to be replaced (tone wheel is not serviced separately). 2. Install the rotor (1) onto the hub/bearing wheel studs (2). 3. Install the caliper adapter assembly (2),See: Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper - Installation and tighten adapter bolts to 176 Nm (130 ft.lbs.). 4. Install the wheel and tire assembly, See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement and lower the vehicle. 5. Apply the brakes several times to seat brake pads. Be sure to obtain firm pedal before moving vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Procedures > Page 5672 Rear REAR 1. Install the rotor (1) to the hub/bearing. 2. Install the caliper adapter (2) See: Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper Adapter - Installation. 3. Install the caliper adapter bolts and tighten the mounting bolts to 135 Nm (100 ft.lbs). 4. Install the disc brake caliper, See: Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper - Installation. 5. Install the tire and wheel assembly See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. 6. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Brake Bleeding Brake Bleeding: Service and Repair Manual Brake Bleeding MANUAL BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. 1. Remove reservoir filler caps and fill reservoir. 2. If calipers were overhauled, open all caliper bleed screws. Then close each bleed screw as fluid starts to drip from it. Top off master cylinder reservoir once more before proceeding. 3. Attach one end of bleed hose (1) to bleed screw and insert opposite end in glass container (2) partially filled with brake fluid. Be sure end of bleed hose is immersed in fluid. NOTE: Bleed procedure should be in this order (1) Right rear (2) Left rear (3) Right front (4) Left front. 4. Open up bleeder, then have a helper press down the brake pedal. Once the pedal is down, hold the pedal down while closing the bleeder. Repeat bleeding until fluid stream is clear and free of bubbles. Then move to the next wheel. 5. Before moving the vehicle verify the pedal is firm and not mushy. 6. Top off the brake fluid and install the reservoir cap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Brake Bleeding > Page 5678 Brake Bleeding: Service and Repair Pressure Brake Bleeding PRESSURE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Follow the manufacturers instructions carefully when using pressure equipment. Do not exceed the tank manufacturers pressure recommendations. Generally, a tank pressure of 15-20 psi is sufficient for bleeding. Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding. Do not pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Brake Bleeding > Page 5679 Brake Bleeding: Service and Repair Antilock Brake System Bleeding ABS BRAKE BLEEDING ABS system bleeding requires conventional bleeding methods plus use of the scan tool. The procedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids. A second base brake bleeding procedure is then required to remove any air remaining in the system. 1. Perform base brake bleeding. See: OR See: . 2. Connect scan tool to the Data Link Connector. 3. Select ANTILOCK BRAKES, followed by MISCELLANEOUS, then ABS BRAKES. Follow the instructions displayed. When scan tool displays TEST COMPLETE, disconnect scan tool and proceed. 4. Perform base brake bleeding a second time. See: . 5. Top off master cylinder fluid level and verify proper brake operation before moving vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Disc Brake Caliper - Description Brake Caliper: Description and Operation Disc Brake Caliper - Description DESCRIPTION The calipers are a single piston type in the rear and dual piston type in the front. The calipers are free to slide laterally, this allows continuous compensation for lining wear. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Disc Brake Caliper - Description > Page 5684 Brake Caliper: Description and Operation Disc Brake Caliper - Operation OPERATION When the brakes are applied fluid pressure is exerted against the caliper piston (2). The fluid pressure is exerted equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bore will be equal. Fluid pressure applied to the piston is transmitted directly to the inboard brake pad (5). This forces the pad lining against the inner surface of the disc brake rotor. At the same time, fluid pressure within the piston bore forces the caliper to slide inward on the mounting bolts. This action brings the outboard brake pad lining (6) into contact with the outer surface of the disc brake rotor. In summary, fluid pressure acting simultaneously on both piston and caliper, produces a strong clamping action. When sufficient force is applied, friction will attempt to stop the rotors from turning and bring the vehicle to a stop. Application and release of the brake pedal generates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and piston return to a rest position. The brake pads do not retract an appreciable distance from the rotor. In fact, clearance is usually at, or close to zero. The reasons for this are to keep road debris from getting between the rotor and lining and in wiping the rotor surface clear each revolution. The caliper piston seal (4) controls the amount of piston (2) extension needed to compensate for normal lining wear. During brake application, the seal is deflected outward by fluid pressure and piston movement(6). When the brakes (and fluid pressure) are released, the seal relaxes and retracts the piston (3). The amount of piston retraction is determined by the amount of seal deflection. Generally the amount is just enough to maintain contact between the piston and inboard brake pad. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures Brake Caliper: Procedures Disc Brake Caliper - Cleaning CLEANING Clean the caliper components with clean brake fluid or brake clean only. Wipe the caliper and piston dry with lint free towels or use low pressure compressed air. CAUTION: Do not use gasoline, kerosene, paint thinner, or similar solvents. These products may leave a residue that could damage the piston and seal. Disc Brake Caliper - Inspection INSPECTION The piston is made from a phenolic resin (plastic material) and should be smooth and clean. The piston must be replaced if cracked or scored. Do not attempt to restore a scored piston surface by sanding or polishing. CAUTION: If the caliper piston is replaced, install the same type of piston in the caliper. Never interchange phenolic resin and steel caliper pistons. The pistons, seals, seal grooves, caliper bore and piston tolerances are different. The bore can be lightly polished with a brake hone (3) to remove very minor surface imperfections. The caliper should be replaced if the bore is severely corroded, rusted, scored, or if polishing would increase bore diameter more than 0.025 mm (0.001 inch). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5687 Brake Caliper: Removal and Replacement Disc Brake Caliper Adapter Mounting Bracket - Removal REMOVAL 1. Remove wheel and tire assembly. 2. Remove the disc brake caliper (3) See: Disc Brake Caliper - Removal. 3. Remove the caliper adapter (2) See: Disc Brake Caliper Adapter - Removal. 4. Remove the rotor (1) See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 5. Remove the axle shaft (1) See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair/Rear Axle - 9 1/4/Removal. 6. Remove the park brake shoes (1) See: Parking Brake System/Parking Brake Shoe/Service and Repair/Removal and Replacement/Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5688 7. Remove the parking brake cable (2) from the brake lever (1). 8. Remove the bolts (2) attaching the support plate to the axle and remove the support plate (1). 9. Remove the caliper adapter mount (1) from the axle housing (2). Disc Brake Caliper Adapter Mounting Bracket - Installation INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5689 1. Install the caliper adapter mount (1) on the axle housing (2). 2. Install support plate (1) on axle flange. Tighten attaching bolts (2) to 64 Nm (47 ft. lbs.). 3. Install parking brake cable (2) in the brake lever (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5690 4. Install the park brake shoes (1) See: Parking Brake System/Parking Brake Shoe/Service and Repair/Removal and Replacement/Installation. 5. Install axle shaft (1), See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair/Rear Axle - 9 1/4/Installation. 6. Adjust brake shoes to drum (2) with brake gauge (1), See: Parking Brake System/Parking Brake Shoe/Adjustments. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5691 7. Install the rotor (1) See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. 8. Install the caliper adapter (2) See: Disc Brake Caliper Adapter - Installation. 9. Install the caliper (3) See: Disc Brake Caliper - Installation. 10. Install wheel and tire assembly. Front FRONT CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support the vehicle. 3. Remove the tire and wheel assembly. 4. Compress the disc brake caliper (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5692 5. Remove the banjo bolt (1) and discard the copper washers (4). 6. Remove the caliper slide pin bolts. 7. Remove the disc brake caliper from the caliper adapter (3). Rear REAR 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support vehicle. 3. Remove the wheel and tire assembly (6). 4. Drain small amount of fluid from master cylinder brake reservoir with suction gun. 5. Remove the brake hose banjo bolt (5) if replacing caliper (4). 6. Remove the caliper mounting slide pin bolts (2). 7. Remove the caliper (4) from vehicle. Front FRONT Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5693 NOTE: Install new copper washers on the banjo bolt when installing 1. Install the disc brake caliper (2) to the brake caliper adapter (3). CAUTION: Verify brake hose (3) is not twisted or kinked before tightening fitting bolt. 2. Install the banjo bolt (1) with new copper washers (4) to the caliper (2). Tighten to 18 Nm (155 in. lbs.) 3. Install the caliper slide pin bolts. Tighten to 32 Nm (24 ft. lbs.) 4. Remove the prop rod from the vehicle. 5. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a complete system bleed procedure must be performed.See: Brake Bleeding/Service and Repair. 6. Install the tire and wheel assembly, See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. 7. Lower the vehicle. Rear REAR 1. Install the caliper (4) to the caliper adapter (7). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5694 2. Coat the caliper mounting slide pin bolts (2) with silicone grease. Then install and tighten the bolts to 15 Nm (11 ft. lbs.). 3. Install the brake hose banjo bolt (5) and new copper seal washers if caliper was removed. CAUTION: Verify that the brake hose is not twisted or kinked before tightening the fitting bolt. 4. Install the brake hose (3) to the caliper (4) using a banjo washer, and tighten bolt to 18 Nm (155 in. lbs.). 5. Remove the prop rod from the vehicle. 6. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair, then a complete system bleed procedure must be performed.See: Brake Bleeding/Service and Repair. 7. Install the wheel and tire assemblies (6). See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. 8. Remove the supports and lower the vehicle. 9. Verify a firm pedal before moving the vehicle. Front FRONT 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the disc brake caliper (1) See: Disc Brake Caliper - Removal. 4. Remove the bolts securing the caliper adapter (2) to the steering knuckle 5. Remove the caliper adapter. Rear REAR 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Drain a small amount of fluid from master cylinder brake reservoir with a clean suction gun. 4. Bottom the caliper pistons into the caliper by prying the caliper over. 5. Remove the caliper mounting bolts. 6. Remove the disc brake caliper from the mount. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5695 CAUTION: Never allow the disc brake caliper to hang from the brake hose. Damage to the brake hose will result. Provide a suitable support to hang the caliper securely. 7. Remove the inboard and outboard brake pads (1). 8. Remove the anti-rattle clips (2). 9. Remove the caliper adapter mounting bolts (4). Front FRONT 1. Install the caliper adapter (1) to the steering knuckle. 2. Install the caliper adapter mounting bolts (2) and tighten to 176 Nm (130 ft.lbs.). 3. Install the disc brake caliper (1)See: Disc Brake Caliper Installation. 4. Install the tire and wheel assembly See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. 5. Remove the support and lower the vehicle. Rear REAR 1. Install the caliper adapter mounting bolts (4). Tighten the mounting bolts to 135 Nm (100 ft.lbs). 2. Install the anti-rattle clips (2). 3. Install the inboard and outboard pads (1). 4. Install the caliper mounting bolts. 5. Install the tire and wheel assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5696 Brake Caliper: Overhaul Disc Brake Caliper - Disassembly DISASSEMBLY 1. Drain the brake fluid from caliper. 2. C-clamp (2) a block of wood (1) over one piston. 3. Take another piece of wood and pad it with one-inch thickness of shop towels (2). Place this piece in the outboard shoe side of the caliper in front of the other piston. This will cushion and protect caliper piston during removal. CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. WARNING: Never attempt to catch the piston as it leaves the bore. This could result in personal injury. 4. To remove the caliper piston direct short bursts of low pressure air with a blow gun through the caliper brake hose port. Use only enough air pressure to ease the piston out. 5. Remove the C-clamp and block of wood from the caliper and clamp it over the dust boot of the first piston removed. This will seal the empty piston bore. 6. Move the padded piece of wood in front of the other piston. 7. Remove the second piston using the same procedure with short bursts of low pressure air. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5697 8. Remove piston dust boots (2) with a suitable pry tool. CAUTION: Do not scratch piston bore while removing the seals. 9. Remove piston seals (3) from caliper (1). 10. Push caliper mounting bolt bushings (3) out of the boot seals (2) and remove the boot seals from the caliper (1). 11. Remove caliper bleed screw. Disc Brake Caliper - Assembly ASSEMBLY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5698 CAUTION: Dirt, oil, and solvents can damage caliper seals. Insure assembly area is clean and dry. NOTE: Verify seal is fully seated and not twisted. 1. Lubricate caliper pistons, piston seals and piston bores with clean, fresh brake fluid. 2. Install new piston seals (3) into caliper bores (2). 3. Lightly lubricate lip of new boot with silicone grease. Install boot on piston and work boot lip into the groove at the top of piston (3). 4. Stretch boot (2) rearward to straighten boot folds, then move boot forward until folds snap into place. 5. Install piston (3) into caliper bore and press piston down to the bottom of the caliper bore by hand or with hammer handle. 6. Seat dust boot in caliper (2) with Handle C-4171 (1) and Installer (3): - 54 mm caliper: Installer C-3716-A 7. Install the second piston and dust boot. CAUTION: Use of alternative grease may cause damage to the boots seals. 8. Lubricate caliper mounting bolt bushings, boot seals and bores with Mopar brake grease or Dow Corning(R) 807 grease only. 9. Install the boot seals into the caliper seal bores and center the seals in the bores. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Procedures > Page 5699 10. Install mounting bolt bushings into the boot seals and insure seal lip is engaged into the bushing grooves at either end of the bushing. 11. Install caliper bleed screw. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Brake Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 5704 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Technical Service Bulletins > Page 5705 Brake Fluid: Specifications Brake Fluid Type Mopar DOT 3 and SAE J1703 should be used. If DOT 3 brake fluid is not available, then DOT 4 is acceptable. Use only recommended brake fluids. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Description and Operation > Brake Fluid - Description Brake Fluid: Description and Operation Brake Fluid - Description BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Description and Operation > Brake Fluid - Description > Page 5708 Brake Fluid: Description and Operation Brake Fluid BRAKE FLUID The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake system. Use only Mopar brake fluid or an equivalent from a tightly sealed container. CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An open container of brake fluid will absorb moisture from the air and contaminate the fluid. CAUTION: Never use any type of a petroleum-based fluid in the brake hydraulic system. Use of such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission fluid, power steering fluid, etc. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Description and Operation > Page 5709 Brake Fluid: Testing and Inspection BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar. If fluid separates into layers, there is mineral oil or other fluid contamination of the brake fluid. If brake fluid is contaminated, drain and thoroughly flush system. Replace master cylinder, proportioning valve, caliper seals, wheel cylinder seals, Antilock Brakes hydraulic unit and all hydraulic fluid hoses. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Description and Operation > Page 5710 Brake Fluid: Service and Repair BRAKE FLUID LEVEL Always clean the master cylinder reservoir (1) and cap (2) before checking fluid level. If not cleaned, dirt could enter the fluid. The fluid fill level is indicated on the side of the master cylinder reservoir (1). The correct fluid level is to the MAX indicator on the side of the reservoir. If necessary, add fluid to the proper level. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5714 Brake Fluid Level Sensor/Switch: Diagrams Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-BRAKE FLUID LEVEL - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Procedures Brake Hose/Line: Procedures Double Inverted Flaring DOUBLE INVERTED FLARING A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available. 1. Cut off damaged tube with Tubing Cutter. 2. Ream cut edges of tubing to ensure proper flare. 3. Install replacement tube nut on the tube. 4. Insert tube in flaring tool. 5. Place gauge form over the end of the tube. 6. Push tubing through flaring tool jaws until tube contacts recessed notch in gauge that matches tube diameter. 7. Tighten the tool bar on the tube 8. Insert plug on gauge in the tube. Then swing compression disc over gauge and center tapered flaring screw in recess of compression disc. 9. Tighten tool handle until plug gauge is squarely seated on jaws of flaring tool. This will start the inverted flare. 10. Remove the plug gauge and complete the inverted flare. ISO Flaring ISO FLARING A preformed metal brake tube is recommended and preferred for all repairs. However, double-wall steel tube can be used for emergency repair when factory replacement parts are not readily available. To make a ISO flare use an ISO flaring tool kit. 1. Cut off damaged tube with Tubing Cutter. 2. Remove any burrs from the inside of the tube. 3. Install tube nut on the tube. 4. Position the tube in the flaring tool flush with the top of the tool bar (6). Then tighten the tool bar on the tube. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Procedures > Page 5719 5. Install the correct size adaptor (1) on the flaring tool yoke screw. 6. Lubricate the adaptor (2). 7. Align the adaptor and yoke screw over the tube. 8. Turn the yoke screw in until the adaptor is squarely seated on the tool bar. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Procedures > Page 5720 Brake Hose/Line: Removal and Replacement Front Hose FRONT HOSE 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support vehicle. 3. Remove the tire and wheel assembly. 4. Loosen the brake line (1) from the brake hose (2) at the frame. 5. Remove the brake line (1) from the brake hose (3) and remove the retaining clip (2) located at the frame. 6. Remove the retaining clip from the brake hose (2). 7. Remove the brake hose banjo bolt at the caliper. 8. Remove the hose. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Procedures > Page 5721 Rear Brake Lines REAR BRAKE LINES 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support the vehicle. NOTE: If brake line (6) is being replaced 3. Remove the brake line (6) from the junction block (2) at the frame, then remove the other end of the line at the caliper hose connection. NOTE: If brake line (1) is being replaced 4. Remove the brake line (1) from the junction block (2) at the frame, then remove the other end of the line at the caliper hose connection. 5. Remove the line being replaced. Caliper Hose Assembly CALIPER HOSE ASSEMBLY NOTE: The axle should be supported in the normal curb position for rear brake hose change. 1. Install prop rod on the brake pedal to keep pressure on the brake system, Holding pedal in this position will isolate master cylinder from hydraulic brake system and will not allow brake fluid to drain out of brake fluid reservoir while brake lines are open. This will allow you to bleed out the area of repair instead of the entire system. 2. Raise and support the vehicle. 3. Remove the brake line going into the brake hose. 4. Remove the mounting bolt for the brake hose at the frame. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Procedures > Page 5722 5. Remove the banjo bolt (4) at the caliper (2) and discard the copper washers (3). 6. Remove the hose (6). Front Brake Hose FRONT BRAKE HOSE 1. Install the brake hose (2) in position. 2. Install the retaining clip (2) for the brake hose (3) at the frame. 3. Install the brake line (1) into the brake hose (2) and tighten to 19 Nm (170 in.lbs). 4. Install the brake hose banjo bolt at the caliper and tighten to 18 Nm (155 in.lbs). 5. Remove the support and lower the vehicle. 6. Remove the prop rod from the vehicle. 7. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a complete system bleed procedure must be performed.See: Brake Bleeding/Service and Repair. Rear Brake Line Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Procedures > Page 5723 REAR BRAKE LINE 1. Install the line. NOTE: If brake line (6) was replaced 2. Install the brake line (6) at the junction block (2) located at the frame. 3. Install the brake line (6) at the brake caliper hose. NOTE: If brake line (1) was replaced 4. Install the brake line (1) at the junction block located at the frame. 5. Install the brake line (1) at the brake caliper hose (6). 6. Lower the vehicle and remove the support. 7. Remove the prop rod from the vehicle. 8. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a complete system bleed procedure must be performed.See: Brake Bleeding/Service and Repair. Caliper Hose Assembly CALIPER HOSE ASSEMBLY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Procedures > Page 5724 1. Install the hose (6). 2. Install the banjo bolt (4) and new cooper washers (3) at the caliper (2). 3. Install the mounting bolt (5) for the brake hose (6) at the frame. 4. Install the brake line (1) into the caliper hose (6). 5. Lower the vehicle and remove the support. 6. Remove the prop rod from the vehicle. 7. Bleed the area of repair for the brake system, If a proper pedal is not felt during bleeding an area of repair then a complete system bleed procedure must be performed.See: Brake Bleeding/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) - Description Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control unit (HCU) - Description DESCRIPTION The HCU consists of a valve body, pump motor, low pressure accumulators, inlet valves, outlet valves and noise attenuators. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > Hydraulic Control unit (HCU) - Description > Page 5729 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Hydraulic Control unit (HCU) - Operation OPERATION Accumulators in the valve body store extra fluid released from the calipers during ABS mode operation. The pump is used to clear the accumulator of brake fluid and is operated by a DC type motor. The motor is controlled by the ABM. The valves modulate brake pressure during antilock braking and are controlled by the ABM. The HCU provides individual pressure control to each front and rear brake. During antilock braking, the solenoid valves are opened and closed as needed. They are cycled rapidly and continuously to modulate pressure and control wheel slip and deceleration. Brake Traction Control and Electronic Stability Program modulate pressure on each wheel individually without any driver brake input. During normal braking, the HCU solenoid valves and pump are not activated. The master cylinder and power booster operate the same as a vehicle without an ABS brake system. During antilock braking, solenoid valve pressure modulation occurs in three stages; pressure increase, pressure hold, and pressure decrease. The valves are all contained in the valve body portion of the HCU. PRESSURE DECREASE The outlet valve is opened and the inlet valve is closed during the pressure decrease cycle. A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the ABM closes the inlet then opens the outlet valve, which also opens the return circuit to the accumulators. Fluid pressure is allowed to bleed off (decrease) as needed to prevent wheel lock. Once the period of high wheel slip has ended, the ABM closes the outlet valve and begins a pressure increase or hold cycle as needed. PRESSURE HOLD Both solenoid valves are closed in the pressure hold cycle but only the inlet valve is energized. Fluid apply pressure in the control channel is maintained at a constant rate. The ABM maintains the hold cycle until sensor inputs indicate a pressure change is necessary. PRESSURE INCREASE The inlet valve is open and the outlet valve is closed during the pressure increase cycle. The pressure increase cycle is used to reapply thew brakes. This cycle controls re-application of fluid apply pressure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control unit (HCU) - Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control unit (HCU) Installation INSTALLATION 1. Reinstall the HCU assembly through the left wheel well. 2. Install HCU assembly on the mounting bracket and Tighten the nuts to 15 Nm (11 ft. lbs.). 3. Install the brake lines (1) to the HCU (4) and tighten to 19 Nm (170 in. lbs.). 4. Install the electrical harness connector (3) to the HCU/ABM assembly (4). 5. Install the chassis lines (1) to the HCU/ABM (2) and tighten to 19 Nm (170 in. lbs.). 6. Install the left front tire. 7. Install negative battery cable to the battery. 8. Remove the brake pedal prop rod. 9. Bleed ABS brake system See: Brake Bleeding/Service and Repair. 10. Connect the scan tool and initialize the ABM by performing the ABS Verification Test See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Hydraulic Control unit (HCU) - Installation > Page 5732 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Control unit (HCU) Removal REMOVAL 1. Remove the negative battery cable from the battery. 2. Install a brake pedal prop rod. 3. Siphon the master cylinder. 4. Disconnect the brake lines (1) from the master cylinder to the HCU (4). 5. Disconnect the chassis lines (2) to the HCU (4). 6. Disconnect the electrical harness connector (3). 7. Remove HCU assembly mounting nuts. 8. Raise and support the vehicle. 9. Remove the left front tire. NOTE: Careful not to lose the mounting pins when remove the HCU from the vehicle. 10. Lift the HCU assembly off the mounting bracket. 11. Remove the HCU assembly through the left wheel well. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Service and Repair > Brake Tube Junction Block - Removal Hydraulic System Junction Block: Service and Repair Brake Tube Junction Block - Removal REMOVAL 1. Remove the brake lines (2) from the junction block (1). 2. Remove the junction block (1) mounting bolt and remove the junction block from the bracket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block > Component Information > Service and Repair > Brake Tube Junction Block - Removal > Page 5737 Hydraulic System Junction Block: Service and Repair Brake Tube Junction Block - Installation INSTALLATION 1. Position the junction block (1) on the bracket and install the mounting bolt. Tighten the mounting bolt to 19 Nm (170 in. lbs.). 2. Install the brake lines (2) into the junction block and tighten to 19 Nm (170 in. lbs.). 3. Bleed the base brake system, See: Brake Bleeding/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Master Cylinder - Description Brake Master Cylinder: Description and Operation Brake Master Cylinder - Description DESCRIPTION A two-piece master cylinder is used on all models. The cylinder body containing the primary and secondary pistons is made of aluminum. The removable fluid reservoir (1) is made of nylon reinforced with glass fiber. The reservoir stores reserve brake fluid for the hydraulic brake circuits and has a switch (4) for indicating low fluid levels. The reservoir is the only serviceable component. The fluid compartments of the nylon reservoir are interconnected to permit fluid level equalization. However, the equalization feature does not affect circuit separation in the event of a front or rear brake malfunction. The reservoir compartments will retain enough fluid to operate the functioning hydraulic circuit. Care must be exercised when removing/installing the master cylinder connecting lines. The threads in the cylinder fluid ports (3) can be damaged if care is not exercised. Start all brake line fittings by hand to avoid cross threading. The cylinder reservoir can be replaced when necessary. However, the aluminum body section (2) of the master cylinder is not a repairable component. NOTE: If diagnosis indicates that an internal malfunction has occurred, the aluminum body section must be replaced as an assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Brake Master Cylinder - Description > Page 5742 Brake Master Cylinder: Description and Operation Brake Master Cylinder - Operation OPERATION The master cylinder bore contains a primary and secondary piston. The primary piston supplies hydraulic pressure to the front brakes. The secondary piston supplies hydraulic pressure to the rear brakes. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 5743 Brake Master Cylinder: Testing and Inspection MASTER CYLINDER/POWER BOOSTER 1. Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum leak. Correct any vacuum leak before proceeding. 2. Stop engine and shift transmission into Neutral. 3. Pump brake pedal until all vacuum reserve in booster is depleted. 4. Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leakage). 5. Start engine and note pedal action. It should fall away slightly under light foot pressure then hold firm. If no pedal action is discernible, power booster, vacuum supply, or vacuum check valve is faulty. Proceed to the POWER BOOSTER VACUUM TEST. 6. If the POWER BOOSTER VACUUM TEST passes, rebuild booster vacuum reserve as follows: Release brake pedal. Increase engine speed to 1500 rpm, close the throttle and immediately turn off ignition to stop engine. 7. Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vacuum assisted pedal applications. If vacuum assist is not provided, booster is faulty. POWER BOOSTER VACUUM TEST 1. Connect vacuum gauge (6) to booster check valve (4) with short length of hose (3) and T-fitting (2). 2. Start and run engine at curb idle speed for one minute. 3. Observe the vacuum supply. If vacuum supply is not adequate, repair vacuum supply. 4. Clamp (1) hose (7) shut between intake vacuum source (5) and check valve (4). 5. Stop engine and observe vacuum gauge (6). 6. If vacuum drops more than one inch HG (33 millibars) within 15 seconds, booster diaphragm or check valve is faulty. POWER BOOSTER CHECK VALVE TEST 1. Disconnect vacuum hose from check valve (1). 2. Remove check valve (1) and valve seal (2) from booster (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Description and Operation > Page 5744 3. Use a hand operated vacuum pump for test. 4. Apply 15-20 inches vacuum at large end of check valve. 5. Plug off the small end to prevent vacuum leakage. 6. Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve is faulty and should be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures Brake Master Cylinder: Procedures MASTER CYLINDER BLEEDING A new master cylinder should be bled before installation on the vehicle. Required bleeding tools include bleed tubes and a wood dowel to stroke the pistons. Bleed tubes can be fabricated from brake line. 1. Mount master cylinder in vise. 2. Attach bleed tubes to cylinder outlet ports (1). Then position each tube end into reservoir (2). 3. Fill reservoir with fresh brake fluid. 4. Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure. Continue bleeding operations until air bubbles are no longer visible in fluid. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5747 Brake Master Cylinder: Removal and Replacement Without ESP WITHOUT ESP 1. Depress the brake pedal five times to deplete any vacuum that may remain in the booster unit. 2. Siphon and drain the fluid from the reservoir. 3. Disconnect the electrical connector (4) for the low fluid level. NOTE: Place a towel or rag under the master cylinder outlet port area to protect the vehicle from brake fluid damage. 4. Remove the brake lines (2) from the master cylinder. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5748 5. Remove the four mounting nuts (2) from the master cylinder (1). 6. Remove the master cylinder.NOTE: Gently ease the master cylinder AND reservoir assembly away from the booster, During removal the master cylinder should be kept as perpendicular to the front of the booster as possible to avoid excess interference with the booster output rod and in order not to dislodge the output rod (2) from its seat inside the booster. With ESP WITH ESP 1. Depress the brake pedal five times to deplete any vacuum that may remain in the booster unit. 2. Siphon and drain the fluid from the reservoir. 3. Disconnect the electrical connector (4) for the low fluid level. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5749 NOTE: Place a towel or rag under the master cylinder outlet port area to protect the vehicle from brake fluid damage. 4. Remove the brake lines (5) from the master cylinder (6). 5. Remove the two mounting nuts (2) from the master cylinder (6). 6. Remove the inner fender well. 7. Remove the fasteners for the integrated power module (IPM) (1). 8. Move the IPM (1) forward to allow clearance to remove the master cylinder (2). 9. Remove the master cylinder (2).NOTE: Gently ease the master cylinder AND reservoir assembly (2) away from the booster (3), During removal the master cylinder should be kept as perpendicular to the front of the booster as possible to avoid excess interference with the booster output rod and in order not to dislodge the output rod (4) from its seat inside the booster. Without ESP WITHOUT ESP NOTE: If master cylinder is replaced bleed cylinder before installation. NOTE: Make sure the output rod (2) of the brake booster is in position and retained by a output rod retaining ring, by looking into the boosters master cylinder mounting hole. This position will enable the output rod to enter inside of the master cylinder plunger sleeve during installation. Proper position is obtained when the output rod is centered perpendicular to the master cylinder mounting hole. NOTE: Prior to installing the master cylinder assembly check that there is a vacuum seal present at the shoulder of the master cylinder flange and it's neck. A round seal must be present to ensure vacuum integrity with the booster. 1. Gently install the master cylinder on the booster mounting studs (1).NOTE: Take precautions to locate the master cylinder plunger over the booster output rod, before installing the master cylinder. If correctly fitted the master cylinder should slide easily onto the booster output rod before the mounting studs are engaged in the flange holes of the master cylinder. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5750 2. Install new mounting nuts (2) and tighten to 10 Nm (90 in. lbs.) 3. Install the brake lines (2) and tighten to 19 Nm (170 in. lbs.). 4. Reconnect the electrical connector (4) for the low fluid level switch. 5. Fill and bleed the base brake system. See: Brake Bleeding/Service and Repair. With ESP WITH ESP Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5751 NOTE: If master cylinder is replaced bleed cylinder before installation. NOTE: Make sure the output rod (4) of the brake booster is in position and retained by a output rod retaining ring, by looking into the boosters master cylinder mounting hole. This position will enable the output rod to enter inside of the master cylinder plunger sleeve during installation. Proper position is obtained when the output rod is centered perpendicular to the master cylinder mounting hole. NOTE: Prior to installing the master cylinder assembly (2) check that there is a vacuum seal present at the shoulder of the master cylinder flange and its neck. A round seal must be present to ensure vacuum integrity with the booster. 1. Gently install the master cylinder (2) on the booster mounting studs (3).NOTE: Take precautions to locate the master cylinder plunger over the booster output rod, before installing the master cylinder. If correctly fitted the master cylinder should slide easily onto the booster output rod before the mounting studs are engaged in the flange holes of the master cylinder. 2. Install the IPM (1) back in place and install the fasteners for the IPM (1) 3. Install the left front wheel well. 4. Install new mounting nuts (2) and tighten to 27 Nm (20 ft. lbs.) 5. Install the brake lines (5) and tighten to 19 Nm (170 in. lbs.). 6. Reconnect the electrical connector (4) for the low fluid level switch. 7. Fill and bleed the base brake system. See: Brake Bleeding/Service and Repair. Brake Master Cylinder Reservoir - Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5752 1. Install the prop rod on the brake pedal to keep pressure on the brake system. 2. Remove the reservoir cap (2) and siphon fluid into a drain container. 3. Disconnect the electrical connector (4) from the fluid level switch in the reservoir (1). 4. Remove the reservoir mounting bolts (2). 5. Remove the reservoir (1) from the master cylinder (3) by pulling upwards and to the side. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5753 6. Remove old seals (1) from the cylinder body (2). Brake Master Cylinder Reservoir - Installation INSTALLATION CAUTION: Do not use any type of tool to install the seals. Tools may cut, or tear the seals creating a leak problem after installation. Install the seals using finger pressure only. 1. Lubricate the new seals (1) with clean brake fluid and Install new seals in cylinder body (2). Use finger pressure to install and seat seals. 2. Start the reservoir (1) in the seals (2). Then rock the reservoir (1) back and forth while pressing downward to seat it into the seals (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Procedures > Page 5754 3. Install the mounting bolts (2) for the reservoir (1) to the master cylinder (3). 4. Reconnect the electrical connector (4) to the fluid reservoir level switch. 5. Remove the prop rod from the vehicle. 6. Fill and bleed base brake system,See: Brake Bleeding/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Backing Plate > Component Information > Service and Repair > Brake Backing Plate - Removal Parking Brake Backing Plate: Service and Repair Brake Backing Plate - Removal REMOVAL 1. Remove wheel and tire assembly. 2. Remove the disc brake caliper See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper Removal. 3. Remove the caliper adapter See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper Adapter Removal. 4. Remove the rotor See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 5. Remove the axle shaft (1) See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair/Rear Axle - 9 1/4/Removal. 6. Remove the park brake shoes (3) See: Parking Brake Shoe/Service and Repair/Removal and Replacement/Removal. 7. Remove the parking brake cable from the brake lever. 8. Remove the four bolts (2) attaching the support plate (1) to the axle and remove the support plate (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Backing Plate > Component Information > Service and Repair > Brake Backing Plate - Removal > Page 5760 Parking Brake Backing Plate: Service and Repair Brake Backing Plate - Installation INSTALLATION 1. Install support plate (1) on axle flange. Tighten attaching bolts (3) to 64 Nm (47 ft. lbs.). 2. Install parking brake cable in the brake lever. 3. Install the park brake shoes (2)See: Parking Brake Shoe/Service and Repair/Removal and Replacement/Installation. 4. Install axle shaft (1), See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair/Rear Axle - 9 1/4/Installation. 5. Adjust brake shoes to drum with brake gauge See: Parking Brake Shoe/Adjustments. 6. Install the rotor See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. 7. Install the caliper adapter See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper Adapter Installation. 8. Install the caliper See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper - Installation. 9. Install the wheel and tire assembly See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal Parking Brake Cable: Service and Repair Removal Front Parking Brake Cable FRONT PARKING BRAKE CABLE 1. Raise and support vehicle. 2. Lockout the parking brake cable (2). 3. Loosen adjusting nut (1) to create slack in front cable. 4. Remove the front cable from the cable connector. 5. Compress cable end fitting at underbody bracket (1) and remove the cable (2) from the bracket. 6. Lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5765 7. Push ball end of cable out of pedal clevis with small screwdriver. 8. Compress cable end fitting (2) at the pedal bracket and remove the cable (1). 9. Remove the left cowl trim and sill plate. 10. Pull up the carpet and remove the cable from the body clip. 11. Pull up on the cable (2) and remove the cable with the body grommet (1). Rear Cable REAR PARK BRAKE CABLE 1. Raise and support the vehicle. 2. Lockout the parking brake cable (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5766 3. Loosen cable adjuster nut (6). 4. Remove the rear park brake cable (5) from the intermediate park brake cable (1). 5. Compress tabs on cable end fitting (3) on the rear park brake cable (4) to the frame mount bracket. Then pull the cable through the bracket. 6. Disengage the park brake cable (2) from behind the rotor assembly. 7. Compress cable tabs on each cable end fitting at the brake cable support plate (1). 8. Remove the cables from the brake cable support plates. Right Rear Cable RIGHT REAR CABLE 1. Raise and support the vehicle. 2. Lockout the parking brake cable (1). 3. Loosen the brake cable at the equalizer and adjuster nut. 4. Remove the right cable from the front cable. 5. Remove the right cable from the equalizer. 6. Remove the cable from the frame bracket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5767 7. Remove the cable (4) from the axle bracket (2). 8. Remove the cable bracket from the shock bracket. 9. Remove the brake cable from the brake lever (3). Left Rear Cable LEFT REAR CABLE 1. Raise and support the vehicle. 2. Lockout the parking brake cable (1). 3. Loosen the brake cable at the equalizer and adjuster nut. 4. Remove the left cable from the front cable. 5. Remove the left cable from the equalizer. 6. Remove the cable from the frame bracket. 7. Remove the cable (4) from the axle bracket (2). 8. Remove the brake cable from the brake lever (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5768 Parking Brake Cable: Service and Repair Installation Front Cable FRONT PARKING BRAKE CABLE 1. From inside the vehicle, insert the cable end fitting (2) into the hole in the pedal assembly (1). 2. Seat the cable retainer in the pedal assembly (1). 3. Engage the cable ball end in clevis on the pedal assembly. 4. Route the cable (2) through the floorpan and install the body grommet (1). 5. Place the carpet down and install the left cowl trim and sill plate. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5769 6. Raise and support the vehicle. 7. Route the cable through the underbody bracket (1) and seat the cable end fitting (2) in the bracket. 8. Connect the cable to the cable connector. 9. Perform the park brake adjustment procedure, See: Parking Brake Tensioner/Adjustments. 10. Lower the vehicle. Rear Cable REAR PARK BRAKE CABLE NOTE: Pull on the cable to ensure it is locked into place. 1. Push each cable end through the brake cable support plate hole until the cable end fitting tabs lock into place. 2. Push the cable (4) through the frame bracket. 3. Lock the left cable end fitting tabs (3) into the frame bracket hole. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5770 4. Install the rear cables (2) into the tensioner rod behind the rear of the brake assembly (1). 5. Install the cable to the intermediate cable connector. 6. Release and remove the lock out device. 7. Perform the park brake adjustment procedure, See: Parking Brake Tensioner/Adjustments. 8. Remove the supports and lower the vehicle. Right Rear Cable RIGHT REAR CABLE 1. Install the brake cable (2) to the brake lever (3). 2. Install the cable bracket to the shock bracket. 3. Install the cable to the axle bracket. 4. Install the cable to the frame bracket. 5. Install the right cable to the equalizer. 6. Install the right cable to the front cable. 7. Adjust the brake cable at the equalizer and using the adjuster nut. Left Rear Cable LEFT REAR CABLE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Removal > Page 5771 1. Install the brake cable (2) to the brake lever (3). 2. Install the cable to the axle bracket. 3. Install the cable to the frame bracket. 4. Install the left cable to the equalizer. 5. Install the left cable to the front cable. 6. Adjust the brake cable at the equalizer and using the adjuster nut. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Removal Parking Brake Pedal: Service and Repair Removal REMOVAL 1. Release the parking brake. 2. Raise the vehicle. 3. Loosen the cable tensioner nut at the equalizer (5) to create slack in the front cable. 4. Lower the vehicle. 5. Remove the steering column opening cover (2), See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 6. Remove the steering column opening reinforcement (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Removal > Page 5776 7. Disconnect the brake lamp wire from the switch on the pedal assembly. 8. Roll the carpet back, loosen the front cable grommet from the floor pan and the cable retainer. 9. Disengage the release rod (1) from the arm on the pedal assembly. 10. Remove the bolts (2) /nuts (1) from the pedal assembly (5) and remove the assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Removal > Page 5777 Parking Brake Pedal: Service and Repair Installation INSTALLATION 1. Position the replacement pedal assembly (5) on the dash and cowl. 2. Install the bolts (2) / nuts (1) and tighten to 14 Nm (125 in. lbs.). 3. Connect the front cable (3) to the arm on the pedal assembly (5). 4. Tighten the front cable grommet (4) to the floor pan and the cable retainer, roll the carpet back. 5. Connect the wires to the brake lamp switch. 6. Install the park brake release rod (1). 7. Install the steering column opening reinforcement. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component Information > Service and Repair > Removal > Page 5778 8. Install the steering column opening cover, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 9. Raise the vehicle. 10. Adjust the parking brake cable tensioner (5)See: Parking Brake Tensioner/Adjustments. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Specifications Parking Brake Shoe: Specifications As a general rule, riveted brake shoes (2) should be replaced when worn to within 0.78 mm (1/32 in.) of the rivet heads. Bonded lining should be replaced when worn to a thickness of 1.6 mm (1/16 in.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Without Adjusting Tool Parking Brake Shoe: Adjustments Without Adjusting Tool PARKING BRAKE SHOES CAUTION: Before adjusting the park brake shoes be sure that the park brake pedal is in the fully released position. If park brake pedal is not in the fully released position, the park brake shoes can not be accurately adjusted. 1. Raise vehicle. 2. Remove tire and wheel. 3. Remove disc brake caliper from caliper adapter See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper - Removal. 4. Remove rotor from the axle shaft See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor Removal. NOTE: When measuring the brake drum diameter, the diameter should be measured in the center of the area in which the park brake shoes contact the surface of the brake drum. 5. Using Brake Shoe Gauge, Special Tool C-3919 (1), or equivalent, accurately measure the inside diameter of the park brake drum portion (2) of the rotor. 6. Using a ruler (2) that reads in 64th of an inch, accurately read the measurement of the inside diameter of the park brake drum from the special tool (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Without Adjusting Tool > Page 5784 7. Reduce the inside diameter measurement of the brake drum that was taken using Special Tool C-3919 (2) by 1/64 of an inch. Reset Gauge, Brake Shoe, Special Tool C-3919 (2) or the equivalent used, so that the outside measurement jaws are set to the reduced measurement. 8. Place Gauge, Brake Shoe, Special Tool C-3919, or equivalent over the park brake shoes. The special tool must be located diagonally across at the top of one shoe and bottom of opposite shoe (widest point) of the park brake shoes. 9. Using the star wheel adjuster, adjust the park brake shoes until the lining on the park brake shoes just touches the jaws on the special tool. 10. Repeat step 8 above and measure shoes in both directions. 11. Install brake rotor on the axle shaft See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor Installation. 12. Rotate rotor to verify that the park brake shoes are not dragging on the brake drum. If park brake shoes are dragging, remove rotor and back off star wheel adjuster one notch and recheck for brake shoe drag against drum. Continue with the previous step until brake shoes are not dragging on brake drum. 13. Install disc brake caliper on caliper adapter See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper - Installation. 14. Install wheel and tire. 15. Tighten the wheel mounting nuts in the proper sequence until all nuts are torqued to half the specified torque. Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.). 16. Lower vehicle. 17. Apply and release the park brake pedal one time. This will seat and correctly adjust the park brake cables. CAUTION: Before moving vehicle, pump brake pedal several times to ensure the vehicle has a firm enough pedal to stop the vehicle. 18. Road test the vehicle to ensure proper function of the vehicle's brake system. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Adjustments > Without Adjusting Tool > Page 5785 Parking Brake Shoe: Adjustments With Adjusting Tool WITH ADJUSTING TOOL Adjustment can be made with a standard brake gauge or with adjusting tool. Adjustment is performed with the complete brake assembly installed on the backing plate. 1. Be sure parking brake lever is fully released. 2. Raise vehicle so rear wheels can be rotated freely. 3. Remove plug from each access hole in brake support plates. 4. Loosen parking brake cable adjustment nut until there is slack in front cable. 5. Insert adjusting tool (4) through support plate access hole (1) and engage tool in teeth of adjusting screw star wheel (2). 6. Rotate adjuster screw star wheel (move tool handle upward) until slight drag can be felt when wheel is rotated. 7. Push and hold adjuster lever away from star wheel with thin screwdriver (3). 8. Back off adjuster screw star wheel until brake drag is eliminated. 9. Repeat adjustment at opposite wheel. Be sure adjustment is equal at both wheels. 10. Install support plate access hole plugs. 11. Adjust parking brake cable and lower vehicle. 12. Depress park brake pedal and make sure park brakes hold the vehicle stationary. 13. Release park brake pedal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Procedures Parking Brake Shoe: Procedures Cleaning CLEANING REAR DRUM IN HAT BRAKE Clean the individual brake components, including the support plate exterior, with a water dampened cloth or with brake cleaner. Do not use any other cleaning agents. Remove light rust and scale from the brake shoe contact pads on the support plate with fine sandpaper. Inspection INSPECTION As a general rule, riveted brake shoes (2) should be replaced when worn to within 0.78 mm (1/32 in.) of the rivet heads. Bonded lining should be replaced when worn to a thickness of 1.6 mm (1/16 in.). Examine the lining contact pattern to determine if the shoes are bent or the drum is tapered. The lining should exhibit contact across its entire width. Shoes (2) exhibiting contact only on one side should be replaced and the drum checked for runout or taper. Inspect the adjuster screw assembly (5). Replace the assembly if the star wheel or threads are damaged, or the components are severely rusted or corroded. Discard the brake springs (3) and retainer components (4) if worn, distorted or collapsed. Also replace the springs if a brake drag condition had occurred. Overheating will distort and weaken the springs. Inspect the brake shoe contact pads on the support plate (1), replace the support plate if any of the pads are worn or rusted through. Also replace the plate (1) if it is bent or distorted. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Procedures > Page 5788 Parking Brake Shoe: Removal and Replacement Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Remove the disc brake caliper,See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper Removal. 4. Remove the disc brake rotor, See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 5. Lockout the parking brake cable (1). 6. Disengage the park brake cable (2) from behind the rotor assembly to allow easier disassembly of the park brake shoes. 7. Remove the axle shaft (1) See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair/Rear Axle - 9 1/4/Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Procedures > Page 5789 8. Disassemble the rear park brake shoes (1). Installation INSTALLATION NOTE: On a new vehicle or after parking brake lining replacement, it is recommended that the parking brake system be conditioned prior to use. This is done by making one stop from 25 mph on dry pavement or concrete using light to moderate force on the parking brake foot pedal. 1. Reassemble the rear park brake shoes (1). 2. Install the axle shaft (1) See: Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/Axle Shaft/Service and Repair/Rear Axle - 9 1/4/Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Procedures > Page 5790 3. Install the park brake cable (2) to the lever behind the support plate (1). 4. Unlock the park brake cable. 5. Adjust the rear brake shoes See: Adjustments. 6. Install the disc brake rotor See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. 7. Install the disc brake caliper See: Disc Brake System/Brake Caliper/Service and Repair/Removal and Replacement/Disc Brake Caliper - Installation. 8. Install the tire and wheel assembly See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. 9. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Tensioner > Component Information > Adjustments Parking Brake Tensioner: Adjustments ADJUSTMENTS NOTE: Tensioner adjustment is only necessary when the tensioner,or a cable has been replaced or disconnected for service. When adjustment is necessary, perform adjustment only as described in the following procedure. This is necessary to avoid faulty park brake operation. 1. Raise the vehicle. 2. Back off the cable tensioner adjusting nut (5) to create slack in the cables. 3. Remove the rear wheel/tire assemblies. Then remove the brake rotorsSee: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 4. Verify the brakes are in good condition and operating properly. 5. Verify the park brake cables operate freely and are not binding, or seized. 6. Check the rear brake shoe adjustment with standard brake gauge See: Parking Brake Shoe/Adjustments. 7. Install the rotors See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation and verify that the rotors rotate freely without drag. 8. Install the wheel/tire assemblies, See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. NOTE: Leave park brakes applied until adjustment is complete. 9. Lower the vehicle enough for access to the park brake foot pedal. Then fully apply the park brakes. 10. Raise the vehicle again. 11. Mark the tensioner rod 6.35 mm (1/4 in.) from edge of the tensioner (2). 12. Tighten the adjusting nut (5) on the tensioner rod until the mark is no longer visible. CAUTION: Do not loosen, or tighten the tensioner adjusting nut for any reason after completing adjustment. 13. Lower the vehicle until the rear wheels are 15-20 cm (6-8 in.) off the shop floor. 14. Release the park brake foot pedal and verify that rear wheels rotate freely without drag. Then lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Description and Operation > Brake/Parking Brake Indicator - Description Parking Brake Warning Lamp: Description and Operation Brake/Parking Brake Indicator Description DESCRIPTION A brake indicator is standard equipment on all instrument clusters. This indicator is located in the center of the speedometer, in the area below and right of the speedometer needle hub. The brake indicator consists of a stencil-like cutout of the word BRAKE (all clusters with a miles-per-hour primary speedometer scale), or the International Control and Display Symbol icon for Brake Failure (all clusters with a kilometers-per-hour primary scale) in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Description and Operation > Brake/Parking Brake Indicator - Description > Page 5798 Parking Brake Warning Lamp: Description and Operation Brake/Parking Brake Indicator Operation OPERATION The brake indicator gives an indication to the vehicle operator when the parking brake is applied, when there are certain brake hydraulic system malfunctions as indicated by a low brake hydraulic fluid level condition, or when the brake fluid level switch is disconnected. The brake indicator can also give an indication when certain faults are detected in the Antilock Brake System (ABS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus, and a hard wired input from the park brake switch. The brake indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the brake indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the brake indicator illuminates for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - Brake Indicator Lamp-On Message - Each time the cluster receives an electronic brake indicator lamp-on message from the CAB, the brake indicator illuminates. The CAB may also send lamp-on messages as feedback during ABS diagnostic procedures. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Park Brake Switch Input - Each time the cluster detects ground on the park brake switch sense circuit (park brake switch closed = park brake applied or not fully released) while the ignition switch is in the ON position, the brake indicator flashes on and off. The indicator continues to flash until the park brake switch sense input to the cluster is an open circuit (park brake switch open = park brake fully released), or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the instrument cluster is put through the self test, the brake indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hardwired ground input to the instrument cluster circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CAB continually monitors the ABS system circuits and sensors, including the brake fluid level switch on the brake master cylinder reservoir, to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction or that the ABS system has become ineffective. The CAB stores a Diagnostic Trouble Code (DTC) for any malfunction it detects. For further diagnosis of the brake indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use conventional diagnostic tools and procedures for the hardwired park brake switch input to the instrument cluster. Refer to the appropriate wiring information. Use a diagnostic scan tool for proper diagnosis of the brake fluid level switch, the ABS, the CAB, the CCN, the CAN data bus or the electronic communication related to brake indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Lamp > Component Information > Description and Operation > Page 5799 Parking Brake Warning Lamp: Testing and Inspection BRAKE INDICATOR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. The hardwired park brake switch input to the instrument cluster, also known as the Cab Compartment Node, (CCN) may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire harness and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CCN, the Controller Antilock Brake (CAB), the Controller Area Network (CAN) data bus or the electronic message inputs also used by the CCN to provide brake indicator operation. The most reliable, efficient and accurate means to diagnose the CCN, the CAB, the CAN data bus or the electronic communication related to brake indicator operation, requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations > Page 5803 Parking Brake Warning Switch: Diagrams Connector - (BODY) 1 WAY SWITCH-PARKING BRAKE - (BODY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description > Page 5806 Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Description and Operation > Page 5807 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. See: Testing and Inspection . If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 5810 Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations > Booster Vacuum Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Locations > Booster Vacuum Sensor > Page 5816 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Diagrams > Booster Vacuum Sensor (HEV) (Headlamp And Dash) 4 Way Brake Booster Vacuum Sensor: Diagrams Booster Vacuum Sensor (HEV) (Headlamp And Dash) 4 Way Connector (HEV) - (HEADLAMP AND DASH) 4 WAY SENSOR-BOOSTER VACUUM (HEV) - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Diagrams > Booster Vacuum Sensor (HEV) (Headlamp And Dash) 4 Way > Page 5819 Brake Booster Vacuum Sensor: Diagrams Vacuum Pressure Sensor (ESP) (Headlamp And Dash) 3 Way Connector (ESP) - (HEADLAMP AND DASH) 3 WAY SENSOR-VACUUM PRESSURE (ESP) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Diagrams > Page 5820 Brake Booster Vacuum Sensor: Description and Operation DESCRIPTION The Vacuum sensor measures the available vacuum in the brake booster. In the event of a Booster failure, the ESP system offers additional brake force to the driver. Utilizing the hydraulic system of ESP, the brake line pressure is increased to achieve a higher deceleration with low pedal force Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Brake Booster Vacuum Sensor > Component Information > Service and Repair > Brake Vacuum Sensor - Removal Brake Booster Vacuum Sensor: Service and Repair Brake Vacuum Sensor - Removal REMOVAL 1. Disconnect the vacuum sensor electrical connector (1). 2. Remove vacuum sensor (1) from the power brake booster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Locations > Page 5826 Vacuum Brake Booster: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 6 WAY SOLENOID-ACTIVE BRAKE BOOSTER (HEV) - (HEADLAMP AND DASH) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Power Brake Booster - Description Vacuum Brake Booster: Description and Operation Power Brake Booster - Description Power Brake Booster 5.7L HEV NOTE: The active brake booster and it's components are serviced as an assembly only. The master cylinder may be replaced separately or as a unit with the active brake booster. The active brake booster assembly consists of a housing divided into separate chambers by two internal diaphragms. The outer edge of each diaphragm is attached to the booster housing (1). Two push rods are used in the booster. The primary push rod connects the booster to the brake pedal. The secondary push rod connects the booster to the master cylinder to stroke the cylinder pistons. Active brake boosters will have a travel sensor (7), vacuum sensor (5), and an active booster solenoid (not shown, behind reservoir). Additionally there is a redesigned primary push rod (to brake pedal) for the regenerative braking system (RBS). Without ESP WITHOUT ESP All models use a tandem diaphragm, power brake booster (3). NOTE: The power brake booster is not a repairable component. The booster must be replaced as an assembly if diagnosis indicates a malfunction has occurred. With ESP WITH ESP Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Power Brake Booster - Description > Page 5829 The booster assembly consists of a housing divided into separate chambers by two internal diaphragms. The outer edge of each diaphragm is attached to the booster housing (1). Two push rods are used in the booster. The primary push rod connects the booster to the brake pedal. The secondary push rod connects the booster to the master cylinder to stroke the cylinder pistons. Power brake boosters with ESP will have a travel sensor (7). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Power Brake Booster - Description > Page 5830 Vacuum Brake Booster: Description and Operation Power Brake Booster - Operation OPERATION WITHOUT 5.7L HEV The booster unit consists of a single housing divided into two by a tandem diaphragm (3). The outer edge of the diaphragm is secured to the housing. A spacer block (2) is located in between the cowl and the booster housing. The booster push rod (1), connects the booster to the brake pedal and master cylinder (4), is attached to the center of the diaphragm. A check valve (5) is used in the booster outlet connected to the engine intake manifold. Power assist is generated by utilizing a combination of vacuum and atmospheric pressure to boost brake assist. WITH 5.7 HEV NOTE: The active brake booster and it's components are serviced as an assembly only. The master cylinder may be replaced separately or as a unit with the active brake booster. The 5.7L HEV active booster has a different design for the booster push rod (1) and uses only three retaining studs (2) and 1 unused stud. The booster push rod (1) connects the booster to the brake pedal and master cylinder and is attached to the center of the diaphragm. A replacement active booster will have a new spacer block and booster push rod with a preset adjustment which should not be changed. A check valve is used in the booster outlet connected to the engine intake manifold and a vacuum pump. Normal power assist is generated by utilizing a combination of vacuum and atmospheric pressure to boost brake application. The 5.7L HEV active booster has a unique operation designed for charging assist of the 300 V battery system. On braking applications the internals of the booster are not directly connected and the booster to master cylinder push rod will not actuate the master cylinder/standard braking system. Under these conditions braking is accomplished through the electric motors within the transmission. If more braking is necessary the active booster can utilize the vacuum supplied by the vacuum pump to actuate the master cylinder. These controls are determined by the antilock brake control (ABS) module (regenerative brake system [RBS]), and under a fault condition concerning regenerative braking, normal vehicle braking takes. There will be slightly more pedal travel when active braking defaults to mechanical/standard braking. Below are the active brake booster specific components. - ACTIVE BRAKE BOOSTER SOLENOIDThe active brake booster solenoid allows the ABS module to actuate the brake booster and apply hydraulic brake pressure via the brake master cylinder without a mechanical link between the brake pedal and booster. The solenoid is controlled via a PWM ground signal from the ABS module. When the solenoid is activated, atmospheric pressure is allowed on the rear side of the booster Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Power Brake Booster - Description > Page 5831 and vacuum is allowed on the front side of the booster to move the master cylinder piston to apply the hydraulic brakes. - BOOSTER TRAVEL SENSORThe travel sensor is a three-wire potentiometer that varies the voltage output as the position of the booster diaphragm changes. The RBS module uses the position information to determine the amount of booster movement and hydraulic brake application. - BOOSTER VACUUM SENSORThe vacuum sensor consists of two signal circuits (redundant for safety) for calculation of brake system operation requirements by the RBS. PRIMARY PUSH RODThe primary push rod is redesigned so the ABS module and active booster will control the hydraulic brakes while the brake pedal simulator unit will operate to give a normal brake pedal feel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5832 Vacuum Brake Booster: Testing and Inspection MASTER CYLINDER/POWER BOOSTER There are separate tests for HEV vehicles and non-HEV vehicles. The steps of the tests are different and in different sequence due to the need to disconnect sensors on the HEV which will set DTCs. MASTER CYLINDER/POWER BOOSTER - WITHOUT HEV 1. Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum leak. Correct any vacuum leak before proceeding. 2. Stop engine and pump brake pedal until all vacuum reserve in booster is depleted. 3. Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leakage). 4. Start engine and note pedal action. It should fall away slightly under light foot pressure then hold firm. If no pedal action is discernible, power booster, vacuum supply, or vacuum check valve is faulty. Proceed to the POWER BOOSTER VACUUM TEST. 5. If the POWER BOOSTER VACUUM TEST passes, rebuild booster vacuum reserve as follows: Release brake pedal. Increase engine speed to 1500 rpm, close the throttle and immediately turn off ignition to stop engine. 6. Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vacuum assisted pedal applications. If vacuum assist is not provided, booster is faulty. POWER BOOSTER VACUUM TEST - WITHOUT HEV 1. Connect vacuum gauge (6) to booster check valve (4) with short length of hose (3) and T-fitting (2). 2. Start and run engine at curb idle speed for one minute. 3. Observe the vacuum gauge. If vacuum supply is not above 12 inches HG (406 millibars), repair vacuum supply. 4. Clamp (1) hose (7) shut between intake vacuum source (5) and check valve (4). 5. Stop engine and observe vacuum gauge (6). 6. If vacuum drops more than one inch HG (33 millibars) within fifteen seconds, booster diaphragm or check valve is faulty. POWER BOOSTER CHECK VALVE TEST - WITHOUT HEV Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5833 1. Disconnect vacuum hose from check valve (1). 2. Remove check valve (1) from booster (3). 3. Use a hand operated vacuum pump for test. 4. Apply 15-20 inches HG (508-677 millibars) vacuum at power booster end of check valve. 5. Plug off the small end (if present) to prevent vacuum leakage. 6. Vacuum should hold steady. If vacuum gauge indicates a vacuum loss, check valve is faulty and should be replaced. POWER BOOSTER VACUUM TEST - HEV 1. Disconnect brake vacuum hose between booster and T-fitting and connect another T-fitting in-line. 2. Connect a vacuum gauge to the T-fitting installed in the previous step. 3. With the hood open, start and run engine at curb idle speed for one minute. 4. Observe the vacuum gauge. If vacuum supply is not above 12 inches HG (406 millibars), repair vacuum supply. 5. Clamp hose shut between T-fitting and engine manifold vacuum source. 6. Stop engine and observe vacuum gauge. 7. If vacuum drops more than one inch HG (33 millibars) within fifteen seconds, booster diaphragm, check valve or original T-fitting is faulty. POWER BOOSTER CHECK VALVE TEST- HEV NOTE: The vacuum line for the booster has a T-fitting with two integrated check valves, one on the engine manifold side, and one on the Electric Vacuum Pump (EVP) side. If this T-fitting/check valves fail, replace only with proper T-fitting. 1. Disconnect the vacuum hose from the T-fitting on the booster side of T-fitting (side without check valve). 2. Connect a hand operated vacuum pump to the T-fitting. 3. Apply 15-20 inches HG (508-677 millibars) of vacuum. Vacuum should hold steady. If gauge on pump indicates vacuum loss, check valve in T-fitting is faulty and T-fitting should be replaced 4. Remove check valve from booster. 5. Connect a hand operated vacuum pump at the power booster end of check valve. 6. Apply 15-20 inches HG (508-677 millibars) of vacuum. 7. Vacuum should hold steady. If gauge on pump indicates vacuum loss, booster check valve is faulty and should be replaced. MASTER CYLINDER/POWER BOOSTER - HEV NOTE: Perform the POWER BOOSTER VACUUM TEST - HEV and the POWER BOOSTER CHECK VALVE TEST- HEV before this test. DTCs will set when performing this test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5834 1. With ignition key off, and door open, press on the brake pedal. The electric vacuum pump (EVP) should come on for approximately 2-5 seconds. If not, EVP or circuits may be faulty, refer to DTC diagnostics. 2. Start engine and check booster vacuum hose connections. A hissing noise indicates vacuum leak. Correct any vacuum leak before proceeding. 3. Turn off engine. 4. Remove the Vacuum Pump Circuit Breaker located in the Power Distribution Center-HEV. 5. Disconnect the harness connector of the Brake Pedal Simulator Cut Off (3). 6. Pump brake pedal until all vacuum reserve in booster is depleted. 7. Press and hold brake pedal under light foot pressure. The pedal should hold firm, if the pedal falls away master cylinder is faulty (internal leakage). NOTE: Several system warning lamps will illuminate on the instrument panel after starting the engine due to the circuit breaker and harness connector disconnect in the previous steps. The last step will clear DTCs and reset these warning lamps. 8. Start engine and note pedal action. It should fall away slightly under light foot pressure then hold firm. If no pedal action is discernible and the Power Booster Vacuum Test - HEV and Power Booster Check Valve Test - HEV have both passed, the power booster is faulty. 9. Increase engine speed to 1500 rpm, close the throttle and immediately turn off ignition to stop engine. Wait a minimum of 90 seconds and try brake action again. Booster should provide two or more vacuum assisted pedal applications. If vacuum assist is not provided, booster is faulty. 10. Stop engine, connect the harness connector of the Brake Pedal Simulator Cut Off (3) and install the Vacuum Pump Circuit Breaker. NOTE: This step must be performed. The warning lamps may not be illuminated after reconnecting all connectors, however the DTCs will need to be cleared 11. Perform the ABS VERIFICATION TEST-HEV See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal Vacuum Brake Booster: Service and Repair Power Brake Booster - Removal Power Brake Booster 5.7 (HEV) 1. Disconnect the 12 Volt battery system ground isolation connector (1). 2. Press the brake pedal five times to deplete any vacuum that may remain in the booster unit. 3. Remove the windshield wiper module.See: Wiper and Washer Systems/Wiper Gear Box/Service and Repair/Wiper Transmission - Removal. 4. Remove the cowl grill support (2) to fender screws (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5837 5. Disconnect the electrical connectors (4, 5, 7 and one behind the master cylinder). 6. Remove the two master cylinder mounting nuts (6). 7. Remove the vacuum hose to the check valve (2), leaving the check valve in the booster. 8. Raise and support the vehicle. 9. Remove the left front wheel. 10. Remove the wheelhouse splash shield. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation. 11. Remove the Intelligent Power Module (IPM) bracket (1) lower mounting bolt (2). 12. Remove the supports and lower the vehicle. 13. Remove the IPM bracket upper mounting bolts (5). 14. Pull forward on the IPM (4) to gain access to move the master cylinder (1) forward, for access to remove the booster (2). NOTE: Gently ease the master cylinder and reservoir assembly (1) away from the booster (2). During removal the master cylinder should be kept as perpendicular to the front of the booster as possible to avoid damage to the master cylinder piston. 15. Move the master cylinder (1) off the booster and forward toward the engine side. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5838 16. Remove and discard the brake lamp switch. See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Removal. 17. Remove the brake booster rod to brake pedal retainer clip (3) and spacer (2). Discard the retainer clip. NOTE: Verify the positioning of the brake booster rod (1) for proper installation. The pad (4) must be positioned so that the spacer (2) can contact the pad (4) when the brakes are applied. 18. Reposition the brake booster rod (1) away from the brake pedal shaft. 19. Remove the three brake booster mounting nuts (1). 20. Remove the booster (2) from the front cowl panel. It may be necessary to have an assistant in the vehicle to pull the booster rod extension toward the center of the vehicle away from the brake pedal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5839 21. Wipe clean any debris from the area of the brake booster cowl mounting hole (1). 22. Remove and transfer any necessary components. Without ESP WITHOUT ESP 1. Depress the brake pedal five times to deplete any vacuum that may remain in the booster unit. 2. Siphon and drain the fluid from the reservoir. 3. Remove the wiper arm (1) and cowl assembly See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal. 4. Remove the brake lamp switch and discard it.Do not reuse the stop lamp switch.See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Removal. 5. Remove clip securing booster push rod to brake pedal (1) See: Brake Pedal Assy/Service and Repair/Brake and/or Accelerator Pedals - Removal. 6. Remove the brake booster mounting nuts (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5840 7. Disconnect the brake level electrical connector (4). 8. Disconnect the brake lines at the master cylinder. 9. Disconnect vacuum line (1) at booster. 10. Remove master cylinder (1) from the mounting studs (2) on the power brake booster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5841 11. Remove the booster (1) and spacer block from front cowl panel. 12. Wipe clean any debris from the brake booster cowl mounting hole (1). With ESP WITH ESP 1. Depress the brake pedal five times to deplete any vacuum that may remain in the booster unit. 2. Siphon and drain the fluid from the reservoir. 3. Remove the wiper arm (1) and cowl assembly See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5842 4. Disconnect the electrical connectors (4,5 and 7). 5. Remove the mounting nuts (6) for the master cylinder. 6. Remove the vacuum hoses to the check valve (2) (DO NOT REMOVE CHECK VALVE). 7. Remove the inner fender well. 8. Remove the fasteners for the integrated power module (IPM) (4). 9. Move the IPM (4) forward to allow clearance to remove the master cylinder (1). NOTE: Gently ease the master cylinder AND reservoir assembly (1) away from the booster (2), During removal the master cylinder should be kept as perpendicular to the front of the booster as possible to avoid excess interference with the booster output rod and in order not to dislodge the output rod (3) from its seat inside the booster. 10. Move the master cylinder (1) off the booster and forward to the engine side. 11. Remove the brake lamp switch and discard it.Do not reuse the stop lamp switch.See: Lighting and Horns/Brake Light Switch/Service and Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5843 Repair/Stop Lamp Switch - Removal. 12. Remove clip securing booster push rod to brake pedal (1) See: Brake Pedal Assy/Service and Repair/Brake and/or Accelerator Pedals - Removal. 13. Remove the brake booster mounting nuts (2). 14. Remove the booster (4) with the spacer block (3) and gasket (2) from front cowl panel. 15. Wipe clean any debris from the brake booster cowl mounting hole (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5844 Vacuum Brake Booster: Service and Repair Power Brake Booster - Installation Power Brake Booster 5.7L (HEV) NOTE: When replacing the power brake booster, the Anti-Lock Brake Module (ABM) must be initialized using the scan tool. To initialize the ABM perform the ABS VERIFICATION TEST - HEV. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test 1. With the booster to cowl gasket in place, guide the booster studs into the cowl panel holes and seat the booster on the panel. It may be necessary to have an assistant in the vehicle to guide the booster rod toward the center of the vehicle away from the brake pedal. 2. Install the three new booster attaching nuts (1) and tighten to 31 Nm (23 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5845 NOTE: Verify the positioning of the brake booster rod (1) for proper installation. The pad (4) must be positioned so that the spacer (2) can contact the pad (4) when the brakes are applied. 3. Install the booster push rod (1) on brake pedal and install the push rod spacer (2) and a new retainer clip (3). CAUTION: Do not reuse the original stop lamp switch. Anytime a switch has been removed or its position compromised, a new switch must be installed and adjusted. Do not attempt to readjust the switch. 4. Install and adjust a NEW stop lamp switch. See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Installation. NOTE: Prior to installing the master cylinder assembly (1), check that there is a vacuum seal present at the shoulder of the master cylinder flange and its neck. A seal must be present to ensure vacuum integrity with the booster. NOTE: Take precautions to locate the master cylinder plunger over the booster output rod before installing the master cylinder. If correctly fitted the master cylinder should slide easily onto the booster output rod before the mounting studs are fully engaged in the flange holes of the master cylinder. 5. Carefully install the master cylinder (1) on the booster mounting studs and install the master cylinder retaining nuts. Tighten the nuts to 25 Nm (18.5 ft. lbs.). 6. Position the Intelligent Power Module (IPM) and install the IPM bracket upper retainer bolts (5). Tighten the bolts to 11.5 Nm (102 in. lbs). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5846 7. Install the vacuum hose to the check valve (2). 8. Reconnect the four electrical connectors (4, 5, 7 and one behind the master cylinder). 9. Raise and support the vehicle. 10. Install the IPM bracket (1) lower bolt (2) and tighten to 11.5 Nm (102 in. lbs). 11. Install the wheelhouse splash shield. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation. 12. Install the wheel. See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. 13. Remove the supports and lower the vehicle. 14. Position the cowl grill support (2) and install the bolts (1). Tighten the bolts to 100 Nm (74 ft. lbs). 15. Install the windshield wiper module. See: Wiper and Washer Systems/Wiper Gear Box/Service and Repair/Wiper Transmission - Installation. 16. Install the cowl plenum cover/grille panel. See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Cover - Installation 17. Install the wiper arms. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5847 18. Connect the 12 Volt battery system ground isolation connector (1). Without ESP WITHOUT ESP 1. Install the spacer block and gaskets if removed. 2. Guide the booster studs into the cowl panel holes and seat the booster (1) on the panel. 3. Install and tighten new booster attaching nuts (2) to 28 Nm (250 in. lbs.). 4. Install the booster push rod (1) on brake pedal and install clip. CAUTION: Do not reuse the original stop lamp switch. Anytime a switch has been removed or its position compromised, a new switch must be installed and adjusted. Do not attempt to readjust the switch. 5. Install and adjust a NEW stop lamp switch. See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5848 6. Install the vacuum hose to the check valve (1). 7. Install the master cylinder (1) on the brake booster and tighten the nuts (2) to 10 Nm (90 in. lbs.). 8. Reconnect the brake fluid level electrical connector (4). 9. Reconnect the brake lines at the master cylinder and tighten the lines to 19 Nm (170 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5849 10. Install the wiper arm and cowl assembly (1) See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation. 11. Fill and bleed the brake system. See: Brake Bleeding/Service and Repair. With ESP WITH ESP 1. Install the spacer block (3) and gaskets (2) if removed. 2. Guide the booster studs (2) into the cowl panel holes and seat the booster on the panel. 3. Install and tighten new booster attaching nuts to 28 Nm (250 in. lbs.). 4. Install the booster push rod (1) on brake pedal and install clip. CAUTION: Do not reuse the original stop lamp switch. Anytime a switch has been removed or its position compromised, a new switch must be installed and adjusted. Do not attempt to readjust the switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5850 5. Install and adjust a NEW stop lamp switch. See: Lighting and Horns/Brake Light Switch/Service and Repair/Stop Lamp Switch - Installation. NOTE: Make sure the output rod (3) of the brake booster is in position and retained by a output rod retaining ring, by looking into the boosters master cylinder mounting hole. This position will enable the output rod to enter inside of the master cylinder plunger sleeve during installation. Proper position is obtained when the output rod is centered perpendicular to the master cylinder mounting hole. NOTE: Prior to installing the master cylinder assembly (1) check that there is a vacuum seal present at the shoulder of the master cylinder flange and its neck. A square seal must be present to ensure vacuum integrity with the booster. NOTE: Take precautions to locate the master cylinder plunger over the booster output rod, before installing the master cylinder. If correctly fitted the master cylinder should slide easily onto the booster output rod before the mounting studs are engaged in the flange holes of the master cylinder. 6. Gently install the master cylinder (1) on the booster mounting studs and tighten the nuts (2) to 10 Nm (90 in. lbs.). 7. Install the IPM (4) back in place and install the fasteners for the IPM (4). 8. Install the left front wheel well. 9. Install the vacuum hose to the check valve (2). 10. Reconnect the electrical connectors (4,5AND7). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Power Brake Booster - Removal > Page 5851 11. Install the wiper arm and cowl assembly (1) See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations > Page 5855 Vacuum Brake Booster Diaphragm Position Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 3 WAY SENSOR-BOOSTER TRAVEL (HEV) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Description DESCRIPTION The travel sensor (7) is mounted on power brake booster (1) below and to the left of the master cylinder, and has one electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description > Page 5858 Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Operation OPERATION The travel sensor is a three-wire potentiometer that varies the voltage output as the position of the booster diaphragm changes. The RBS module uses the position information to determine the amount of booster movement and hydraulic brake application. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor - Removal REMOVAL 1. Disconnect the electrical connector (2) from the travel sensor (1). NOTE: The retainer clip does not need to be removed, only pushed up slightly to disengage the tabs on the sensor. 2. Using a small screw driver (4) or another suitable tool, push up on the retainer clip (2) and pull the travel sensor (3) from the power brake booster (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal > Page 5861 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor Installation INSTALLATION NOTE: When replacing the travel sensor, the Anti-Lock Brake Module (ABM) must be initialized using the scan tool. To initialize the ABM perform the ABS VERIFICATION TEST - HEV. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test . NOTE: Verify that the surface is clean, the old O-ring is removed, and the new O-ring is properly positioned on the sensor. 1. With a slight twisting motion, push the travel sensor (3) into the power brake booster (1). There should be a slight snapping sound as the retainer clip (3) seats into position. 2. Verify that the travel sensor retainer clip (3) snapped into place. 3. Connect the electrical connector (2) to the travel sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Locations > Page 5865 Vacuum Pump: Diagrams Connector (HEV) - ENGINE 2 WAY PUMP-BRAKE VACUUM (HEV) - ENGINE 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Description and Operation > Description Vacuum Pump: Description and Operation Description DESCRIPTION The electric vacuum pump (2) is used on the 5.7L HEV. The pump is mounted on the LF of the engine with one upper bolt (3) and nut (1), and two lower bolts (4). There is one electrical connector and one vacuum hose connected to it. The positive battery cable access is mounted to the top of the vacuum pump mounting bracket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Description and Operation > Description > Page 5868 Vacuum Pump: Description and Operation Operation OPERATION The electric vacuum pump is used on the 5.7L HEV to provide vacuum to the active brake booster during periods of time when the engine is not running but vacuum is needed by the brake booster. The electric vacuum pump is relay controlled by the ABS module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Description and Operation > Page 5869 Vacuum Pump: Testing and Inspection VACUUM PUMP FUNCTIONAL TEST Check for DTCs prior to performing this test because this test may cause DTCs to set in the Antilock Brake Module (ABS). Any fault in the voltage/ground circuits of the Electric Vacuum Pump (EVP) will cause vacuum sensor DTCs to set in the ABS, therefore this test only checks the vacuum output of a functioning EVP. 1. Disconnect the vacuum hose from the T-fitting on the booster side of T-fitting (side without check valve). 2. Connect a hand operated vacuum pump to the T-fitting. 3. With ignition key off, and door open, press on the brake pedal. The EVP should come on for approximately 5-10 seconds. If not, EVP or circuits may be faulty, refer to DTC diagnostics. The pump should increase vacuum gauge reading to above 22 inches HG (745 millibars) of vacuum. If not, and no leaks are present AND there are no DTCs, replace the EVP See: Service and Repair/Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Service and Repair > Removal Vacuum Pump: Service and Repair Removal REMOVAL 1. Disconnect the 12 volt battery system ground isolation connector (1), and remove connector from the bracket (2). 2. Remove the vacuum hose (3) from the electric vacuum pump. 3. Disconnect the electrical connector (4) from the electric vacuum pump. NOTE: Before removal, observe the orientation of the two battery cables (3) to properly position during installation. 4. Lift the positive battery cable access cover (1) and remove the positive battery cable nut (2). Position the positive battery cables (3) aside for access. 5. Remove the battery cable junction block bolt (4) and position the battery cable junction block aside for access to remove the electric vacuum pump. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Service and Repair > Removal > Page 5872 NOTE: The top bolt is through the pump with a nut on the back. 6. Remove the upper vacuum pump bracket bolt (2) and nut. 7. Remove the lower vacuum pump bracket bolts (5). 8. Remove and transfer any necessary components. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Service and Repair > Removal > Page 5873 Vacuum Pump: Service and Repair Installation INSTALLATION 1. Install the vacuum pump (3). - Place a lower bolt (5) through the electrical harness/air conditioning tube retainer bracket (4) for installation in the bottom bolt position on the electric vacuum pump bracket (1) and install the lower bolts (5) but do not tighten. - Install the upper bolt and nut (2). Tighten the upper bolt and nut to 40 Nm (29.5 ft. lbs.). - Tighten the lower bolts (5) to 20 Nm (15 ft. lbs.). 2. Position the battery cable junction block with the tab in the alignment hole and install the battery cable junction block retainer bolt (4) finger tight only. NOTE: For proper connections, ensure that the two battery cables (3) are positioned as observed during removal and DO NOT stack the crimp of the top terminal directly above the crimp of the bottom terminal. 3. Position the positive battery cables (3) over the studs and install the positive battery cable nuts (2). Tighten the nuts to 10 Nm (90 in. lbs.). 4. Secure the positive battery cable access cover (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump, Brakes > Component Information > Service and Repair > Removal > Page 5874 5. Connect the electrical connector (4) to the vacuum pump. 6. Connect the vacuum hose (3) to the vacuum pump. 7. Connect the 12 volt battery system ground isolation connector (1), and reattach to the bracket (2). 8. Using a scan tool, reset the Vacuum Pump Wear Out Counter in the Antilock Brake Module (ABS) under Miscellaneous Tests. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump Relay, Brakes > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Pump Relay, Brakes > Component Information > Locations > Page 5878 Vacuum Pump Relay: Diagrams Connector (HEV) - (IN PDC) RELAY-VACUUM PUMP (HEV) - (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Antilock Brake Module (Headlamp And Dash Side) 38 Way Electronic Brake Control Module: Diagrams Antilock Brake Module (Headlamp And Dash Side) 38 Way Connector - (HEADLAMP AND DASH SIDE) 38 WAY MODULE-ANTILOCK BRAKES - (HEADLAMP AND DASH SIDE) 38 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Antilock Brake Module (Headlamp And Dash Side) 38 Way > Page 5885 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Antilock Brake Module (Headlamp And Dash Side) 38 Way > Page 5886 Electronic Brake Control Module: Diagrams Antilock Brake Module (HEV) (Headlamp And Dash) 47 Way Connector (HEV) - (HEADLAMP AND DASH) 47 WAY MODULE-ANTILOCK BRAKES (HEV) - (HEADLAMP AND DASH) 47 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Antilock Brake Module (Headlamp And Dash Side) 38 Way > Page 5887 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module Description Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Description DESCRIPTION The Antilock Brake Module (ABM) is a microprocessor which handles testing, monitoring and controlling the ABS brake system operation. The ABM is mounted on the top of the hydraulic control unit (HCU). The ABM operates the ABS system and is separate from other vehicle electrical circuits. ABM voltage source is through CKT A111 (fused B+). NOTE: If the ABM needs to be replaced, Perform the ABS verification using a scan tool. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module Description > Page 5890 Electronic Brake Control Module: Description and Operation Anti-Lock Brake System Module Operation ABS Unit ABS UNIT SYSTEM SELF-TEST When the ignition switch is turned-on the microprocessor is tested. If an error occurs during the test, a DTC will be set into the memory. However it is possible the DTC will not be stored in memory if the error has occurred in the module were the DTC's are stored. The ABM contains a self check program that illuminates the ABS warning light when a system fault is detected. Faults are stored in memory and are accessible with the scan tool. ABS faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. ABM INPUTS The ABM continuously monitors the speed of the vehicle by monitoring signals generated by the wheel speed sensors. The ABM determines a wheel locking tendency when it recognizes the axle is decelerating too rapidly. The ABM monitors the following inputs to determine when a wheel locking tendency may exists: - Wheel Speed Sensors - Brake Lamp Switch - Brake Fluid Level Sensor (CAN C BUS) - G-Sensor (4X4) ABM OUTPUTS The ABM requests the following outputs for antilock braking and brake warning information from the CCN via CAN C Bus: - ABS Warning Lamp - Brake Warning Lamp ESP Unit ESP UNIT - (ELECTRONIC STABILITY PROGRAM) SYSTEM SELF-TEST When the ignition switch is turned-on the microprocessor is tested. If an error occurs during the test, a DTC will be set into the memory. However it is possible the DTC will not be stored in memory if the error has occurred in the module were the DTC's are stored. The ABM contains a self check program that illuminates the ABS and ESP warning lights when a ABS system fault is detected. If only the ESP light is illuminated ESP system fault is detected. Faults are stored in memory and are accessible with the scan tool. System faults remain in memory until cleared, or until after the vehicle is started approximately 50 times. Stored faults are not erased if the battery is disconnected. ABM INPUTS The ABM continuously monitors the speed of the vehicle by monitoring signals generated by the wheel speed sensors. The ABM determines a wheel locking tendency when it recognizes the axle is decelerating too rapidly. The ABM monitors the following inputs to determine when a wheel locking tendency may exists: - Wheel Speed Sensors - Brake Lamp Switch - Brake Fluid Level Sensor (CAN C BUS) - Steering Angle Sensor (SAS) (CAN C BUS) - Dynamic Sensor - ESP Off Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Description and Operation > Anti-Lock Brake System Module Description > Page 5891 - Vacuum Sensor ABM OUTPUTS The ABM requests the following outputs for antilock braking and brake warning information from the CCN via CAN C Bus: - ABS Warning Lamp - Brake Warning Lamp - ESP Warning Lamp - ESP Function Lamp Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal Electronic Brake Control Module: Service and Repair Anti-Lock Brake System Module - Removal REMOVAL CAUTION: When removing ABM from HCU, be sure to completely separate the two components (approximately 38 mm (1.5 in.) before removing ABM. Otherwise, damage to the pressure sensor or Pump Motor connection may result requiring HCU replacement. Do not to touch the sensor terminals on the HCU side or the contact pads on the ABM side as this may result in contamination and issues in the future. NOTE: ABM module can be removed without removing the HCU unit. 1. Remove the left front tire and wheel assembly. 2. Disconnect the electrical connector from the ABM module. 3. Remove the module mounting screws (2). 4. Remove the module from the HCU (1) on ESP vehicles be careful not to damage the pressure sensor or not to touch the sensor terminals on the HCU side or the contact pads on the ABM side when removing the ABM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Anti-Lock Brake System Module - Removal > Page 5894 Electronic Brake Control Module: Service and Repair Anti-Lock Brake System Module - Installation INSTALLATION CAUTION: When removing ABM from HCU, be sure to completely separate the two components (approximately 38 mm (1.5 in.) before removing ABM. Otherwise, damage to the pressure sensor or Pump Motor connection may result requiring HCU replacement. Do not to touch the sensor terminals on the HCU side or the contact pads on the ABM side as this may result in contamination and issues in the future. 1. Position the module on the HCU on ESP vehicles be careful not to damage the pressure sensor or not to touch the sensor terminals on the HCU side or the contact pads on the ABM side when installing the ABM. 2. Install the mounting screws (2) and tighten to 2.5 Nm (22 in. lbs). 3. Connect the scan tool and initialize the ABM by performing the ABS Verification Test See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Vacuum Pump Relay, Brakes > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Vacuum Pump Relay, Brakes > Component Information > Locations > Page 5898 Vacuum Pump Relay: Diagrams Connector (HEV) - (IN PDC) RELAY-VACUUM PUMP (HEV) - (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Booster Vacuum Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Locations > Booster Vacuum Sensor > Page 5904 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams > Booster Vacuum Sensor (HEV) (Headlamp And Dash) 4 Way Brake Booster Vacuum Sensor: Diagrams Booster Vacuum Sensor (HEV) (Headlamp And Dash) 4 Way Connector (HEV) - (HEADLAMP AND DASH) 4 WAY SENSOR-BOOSTER VACUUM (HEV) - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams > Booster Vacuum Sensor (HEV) (Headlamp And Dash) 4 Way > Page 5907 Brake Booster Vacuum Sensor: Diagrams Vacuum Pressure Sensor (ESP) (Headlamp And Dash) 3 Way Connector (ESP) - (HEADLAMP AND DASH) 3 WAY SENSOR-VACUUM PRESSURE (ESP) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Diagrams > Page 5908 Brake Booster Vacuum Sensor: Description and Operation DESCRIPTION The Vacuum sensor measures the available vacuum in the brake booster. In the event of a Booster failure, the ESP system offers additional brake force to the driver. Utilizing the hydraulic system of ESP, the brake line pressure is increased to achieve a higher deceleration with low pedal force Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Booster Vacuum Sensor > Component Information > Service and Repair > Brake Vacuum Sensor - Removal Brake Booster Vacuum Sensor: Service and Repair Brake Vacuum Sensor - Removal REMOVAL 1. Disconnect the vacuum sensor electrical connector (1). 2. Remove vacuum sensor (1) from the power brake booster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 5914 Brake Fluid Level Sensor/Switch: Diagrams Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-BRAKE FLUID LEVEL - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Brake Pedal Angle Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Locations > Brake Pedal Angle Sensor > Page 5919 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Brake Pedal Angle Sensor (Headlamp And Dash) 6 Way Braking Sensor/Switch: Diagrams Brake Pedal Angle Sensor (Headlamp And Dash) 6 Way Connector - (HEADLAMP AND DASH) 6 WAY SENSOR-BRAKE PEDAL ANGLE - (HEADLAMP AND DASH) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Braking Sensor/Switch > Component Information > Diagrams > Brake Pedal Angle Sensor (Headlamp And Dash) 6 Way > Page 5922 Braking Sensor/Switch: Diagrams Brake Pedal Pressure Sensor (HEV) (Headlamp And Dash) 3 Way Connector (HEV) - (HEADLAMP AND DASH) 3 WAY SENSOR-BRAKE PEDAL PRESSURE (HEV) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams > Dynamics Sensor (ESP) (Instrument Panel) 4 Way Lateral Accelerometer: Diagrams Dynamics Sensor (ESP) (Instrument Panel) 4 Way Connector (ESP) - (INSTRUMENT PANEL) 4 WAY SENSOR-DYNAMICS (ESP) - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Diagrams > Dynamics Sensor (ESP) (Instrument Panel) 4 Way > Page 5928 Lateral Accelerometer: Diagrams Dynamics Sensor (HEV) (Instrument Panel) 6 Way Connector (HEV) - (INSTRUMENT PANEL) 6 WAY SENSOR-DYNAMICS (HEV) - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Description and Operation > Dynamics Sensor - Description Lateral Accelerometer: Description and Operation Dynamics Sensor - Description DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (2). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor (2) must be replaced when necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Description and Operation > Dynamics Sensor - Description > Page 5931 Lateral Accelerometer: Description and Operation G Sensor - Description DESCRIPTION The G-sensor is located only inside the ABS controller 4x4 only. The sensor is not a separate serviceable part from the antilock brake module (ABM). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal Lateral Accelerometer: Service and Repair Dynamics Sensor - Removal REMOVAL 1. Remove the center console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Removal. 2. Disconnect electrical connector (3) from the dynamics sensor (2). 3. Remove the two nuts (1) securing the sensor to the floor. 4. Remove the sensor (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Lateral Accelerometer > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 5934 Lateral Accelerometer: Service and Repair Dynamics Sensor - Installation INSTALLATION 1. Install the dynamics sensor (2) on the studs (4) to the vehicle. NOTE: Make sure the electrical connector is facing toward the rear of the vehicle. 2. Connect the electrical connector (3) to the sensor (2). 3. Install the two retaining nuts (1) and tighten to 6 Nm (53 in. lbs.). 4. Install the floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Installation. 5. Perform the ABS verification test with the scan tool. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations > Page 5938 Parking Brake Warning Switch: Diagrams Connector - (BODY) 1 WAY SWITCH-PARKING BRAKE - (BODY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description > Page 5941 Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Description and Operation > Page 5942 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. See: Testing and Inspection . If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 5945 Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 5949 Steering Angle Sensor: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SENSOR-STEERING ANGLE - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Locations > Page 5950 Steering Angle Sensor: Description and Operation DESCRIPTION NOTE: Steering angle sensor is part of the airbag clockspring and is not serviced separately from the clockspring. The steering angle sensor is used to measure the driver intended path in the ESP system. Based on the deviation between steering wheel input and the Yaw Rate signal from the dynamic sensor, ESP can be activated. The SAS should be mounted correctly to ensure that the system functions properly and there are not inadvertent activations. Any replacement of the steering angle sensor requires that the ABS verification test be performed. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Service and Repair > Removal Steering Angle Sensor: Service and Repair Removal REMOVAL NOTE: Steering angle sensor is part of the airbag clockspring and is not serviced separately from the clockspring. 1. For removal of the steering angle sensor See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement/Clockspring - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Steering Angle Sensor, Traction Control > Component Information > Service and Repair > Removal > Page 5953 Steering Angle Sensor: Service and Repair Installation INSTALLATION NOTE: Steering angle sensor is part of the airbag clockspring and is not serviced separately from the clockspring. 1. For installation of the steering angle sensor See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement/Clockspring - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Locations > Page 5957 Traction Control Switch: Diagrams Connector - (INSTRUMENT PANEL) 2 WAY SWITCH-TRACTION CONTROL - (INSTRUMENT PANEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations > Page 5961 Vacuum Brake Booster Diaphragm Position Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 3 WAY SENSOR-BOOSTER TRAVEL (HEV) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor Description Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Description DESCRIPTION The travel sensor (7) is mounted on power brake booster (1) below and to the left of the master cylinder, and has one electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor Description > Page 5964 Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Operation OPERATION The travel sensor is a three-wire potentiometer that varies the voltage output as the position of the booster diaphragm changes. The RBS module uses the position information to determine the amount of booster movement and hydraulic brake application. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor - Removal REMOVAL 1. Disconnect the electrical connector (2) from the travel sensor (1). NOTE: The retainer clip does not need to be removed, only pushed up slightly to disengage the tabs on the sensor. 2. Using a small screw driver (4) or another suitable tool, push up on the retainer clip (2) and pull the travel sensor (3) from the power brake booster (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal > Page 5967 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor Installation INSTALLATION NOTE: When replacing the travel sensor, the Anti-Lock Brake Module (ABM) must be initialized using the scan tool. To initialize the ABM perform the ABS VERIFICATION TEST - HEV. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test . NOTE: Verify that the surface is clean, the old O-ring is removed, and the new O-ring is properly positioned on the sensor. 1. With a slight twisting motion, push the travel sensor (3) into the power brake booster (1). There should be a slight snapping sound as the retainer clip (3) seats into position. 2. Verify that the travel sensor retainer clip (3) snapped into place. 3. Connect the electrical connector (2) to the travel sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 5972 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 5973 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Locations > Left Front Wheel Speed Sensor > Page 5974 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way Wheel Speed Sensor: Diagrams Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT FRONT - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way > Page 5977 Wheel Speed Sensor: Diagrams Left Rear Wheel Speed Sensor (Chassis) 2 Way Connector - (CHASSIS) 2 WAY SENSOR-WHEEL SPEED-ABS-LEFT REAR - (CHASSIS) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way > Page 5978 Wheel Speed Sensor: Diagrams Right Front Wheel Speed Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT FRONT - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Left Front Wheel Speed Sensor (Headlamp And Dash) 2 Way > Page 5979 Wheel Speed Sensor: Diagrams Right Rear Wheel Speed Sensor (Chassis) 2 Way Connector - (CHASSIS) 2 WAY SENSOR-WHEEL SPEED-ABS-RIGHT REAR - (CHASSIS) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Diagrams > Page 5980 Wheel Speed Sensor: Description and Operation OPERATION The sensors convert wheel speed into a digital signal. The ABM sends 12 volts to the sensors. The sensor has an internal hall sensor that alters the voltage and amperage of the signal circuit. This voltage and amperage is changed by magnetic induction when the toothed tone wheel passes the wheel speed sensor. This digital signal is sent to the ABM. The ABM measures the voltage and amperage of the digital signal for each wheel. The signal strength is affected by the distance between the Sensor and the tone ring. If the "Air Gap" between the WSS and the tone ring/wheel is too large, the WSS signal can drop out at low speed, (below 40 mph) and can cause an ABS activation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Removal Front REMOVAL 1. Remove the front rotor See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 2. Remove the wheel speed sensor mounting bolt (1) from the hub (3). 3. Remove the wheel speed sensor (2) from the hub (3). 4. Remove the wiring from the clips and disconnect the electrical connector. Rear REMOVAL 1. Raise the vehicle on a hoist. 2. Disconnect the wheel speed sensor electrical connector (3). 3. Remove the mounting bolt (1) from the sensor (4). 4. Remove the sensor (4) from the brake caliper adapter (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor - Removal > Page 5983 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor - Installation Front INSTALLATION 1. Install the wiring to the clips and Reconnect the electrical connector. 2. Install the wheel speed sensor (2) to the hub (3). 3. Install the wheel speed sensor mounting bolt (1) to the hub (3). Tighten the bolt to 21 Nm (190 in. lbs.). 4. Install the front rotor and brake caliper assembly See: Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. Rear INSTALLATION 1. Insert the wheel speed sensor (4) in the brake caliper adapter (2). 2. Install the sensor mounting bolt (1) and tighten to 24 Nm (200 in. lbs.). 3. Reconnect the electrical wiring connector (3) to the sensor (4). 4. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams > Dynamics Sensor (ESP) (Instrument Panel) 4 Way Yaw Rate Sensor: Diagrams Dynamics Sensor (ESP) (Instrument Panel) 4 Way Connector (ESP) - (INSTRUMENT PANEL) 4 WAY SENSOR-DYNAMICS (ESP) - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Diagrams > Dynamics Sensor (ESP) (Instrument Panel) 4 Way > Page 5989 Yaw Rate Sensor: Diagrams Dynamics Sensor (HEV) (Instrument Panel) 6 Way Connector (HEV) - (INSTRUMENT PANEL) 6 WAY SENSOR-DYNAMICS (HEV) - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Description and Operation > Dynamics Sensor - Description Yaw Rate Sensor: Description and Operation Dynamics Sensor - Description DESCRIPTION The Yaw Rate and Lateral Acceleration Sensors are housed into one unit known as the Dynamics Sensor (2). The sensor is used to measure side-to-side (Lateral) motion and vehicle rotational sensing (how fast the vehicle is turning - Yaw). Yaw and Lateral Acceleration Sensors cannot be serviced separately. The entire Dynamics Sensor (2) must be replaced when necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Description and Operation > Dynamics Sensor - Description > Page 5992 Yaw Rate Sensor: Description and Operation G Sensor - Description DESCRIPTION The G-sensor is located only inside the ABS controller 4x4 only. The sensor is not a separate serviceable part from the antilock brake module (ABM). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal Yaw Rate Sensor: Service and Repair Dynamics Sensor - Removal REMOVAL 1. Remove the center console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Removal. 2. Disconnect electrical connector (3) from the dynamics sensor (2). 3. Remove the two nuts (1) securing the sensor to the floor. 4. Remove the sensor (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Yaw Rate Sensor > Component Information > Service and Repair > Dynamics Sensor - Removal > Page 5995 Yaw Rate Sensor: Service and Repair Dynamics Sensor - Installation INSTALLATION 1. Install the dynamics sensor (2) on the studs (4) to the vehicle. NOTE: Make sure the electrical connector is facing toward the rear of the vehicle. 2. Connect the electrical connector (3) to the sensor (2). 3. Install the two retaining nuts (1) and tighten to 6 Nm (53 in. lbs.). 4. Install the floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Installation. 5. Perform the ABS verification test with the scan tool. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Removal REMOVAL 1. Disconnect negative cable from battery. 2. Remove the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 3. Remove the tilt lever handle. 4. Remove the lower shroud (2) from steering column. 5. Place shifter in PARK position. The ignition key (2) must be in the key cylinder (1) for cylinder removal. 6. A retaining pin is located at side of key cylinder assembly. a. Rotate key (2) to RUN position. b. Press in on retaining pin with a small punch (3) , while pulling key cylinder (1) from ignition switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 6003 7. Remove the key (2) and key cylinder (1) from the column (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 6004 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Installation INSTALLATION The ignition key (2) must be in the key cylinder (1) for cylinder installation. 1. Install the key cylinder (1) into the housing (3) using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder (1) in until it clicks. 3. Replace the lower shroud. 4. Install the tilt lever handle. 5. Install the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 6. Reconnect the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Starter Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations > Page 6009 Starter Relay: Diagrams Connector (IN PDC) RELAY-STARTER MOTOR (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Starter Relay - Description Starter Relay: Description and Operation Starter Relay - Description DESCRIPTION The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See the power distribution center cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Starter Relay - Description > Page 6012 Starter Relay: Description and Operation Starter Relay - Operation OPERATION The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Service and Repair > Starter Relay - Removal Starter Relay: Service and Repair Starter Relay - Removal REMOVAL The starter relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Disconnect and isolate negative battery cable. 2. Remove cover from Power Distribution Center (PDC) for relay identification and location. 3. Remove starter relay from PDC. 4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Service and Repair > Starter Relay - Removal > Page 6015 Starter Relay: Service and Repair Starter Relay - Installation INSTALLATION 1. Push down firmly on starter relay until terminals are fully seated into PDC receptacle. 2. Install PDC cover. 3. Connect battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service and Repair Jump Starting: Service and Repair JUMP STARTING - HYBRID ELECTRIC VEHICLES (HEV) VEHICLES ONLY WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Review all safety precautions and warnings in the battery system section. See: Service and Repair/Procedures/Battery Charging - Do not jump start a frozen battery. - Do not jump start a maintenance-free battery (if equipped) when indicator dot is yellow or a bright color. - Do not jump start a vehicle when the battery fluid is below the top of lead plates. - Do not allow jumper cable clamps to touch each other when connected to a booster source. Do not expose battery to or near open flame. - Remove metallic jewelry worn on hands or wrists to avoid injury by accidental arcing of battery current. - When using a high-output boosting device, do not allow battery voltage to exceed 16 volts. Refer to instructions provided with device being used. Failure to follow these instructions may result in personal injury. CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle. TO JUMP START A DISABLED VEHICLE: This Hybrid vehicle is equipped with both a 12 Volt battery and a high voltage battery. Either battery may become discharged and cause a no crank condition as a result of low voltage. If the 12 Volt battery state of charge is to low and the engine will not crank, the 12 Volt battery light located in the cluster, may illuminate. If this occurs refer to "Jump-Starting - 12 Volt Battery". If the high voltage battery state of charge is too low and the engine will not crank, the navigation radio displays a "Charge Insufficient" message. If this occurs refer to "Jump Assist Procedure High Voltage Battery". Jump Assist Procedure - High Voltage Battery NOTE: When running the Jump Assist mode with the scan tool, ensure the High Voltage Battery contactors are in the close positions. Using the scan tool view the High Voltage Battery contactors status in the BPCM. If the High Voltage Battery contactors are opened, the jump assist will not operate. If this happens, cycle the ignition key from off and on without an attempted crank. The "Jump Assist" procedure allows you to charge the high voltage battery using the 12 Volt battery system. The navigation radio guides you through the "Jump Assist" procedure. This message indicates that the vehicle is in "Jump Assist" mode, and can be charged by following the "Jump Assist" procedure. You have approximately 15 minutes to connect a 12 Volt battery charger and begin charging the system. If you are unable to connect a 12 Volt battery charger within 15 minutes, turn the ignition key to the START position to re-initiate "Jump Assist" mode. NOTE: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service and Repair > Page 6020 - depending on the high voltage battery state of charge, it may take up to 60 minutes for the system to become adequately charged to start the engine. - there are remote battery posts located under the hood that are used to assist in the "Jump Assist" procedure. a second running vehicle may be used in this "Jump Assist" procedure provided the generator output is a minimum of 125 amps. WARNING: - a battery generates hydrogen gas which is flammable and explosive. Keep flame or spark away from the vent holes. Do Not use a booster battery or any other booster source with a nominal voltage output that exceeds 12 Volts. - battery fluid is a corrosive acid solution; do not allow battery fluid to contact eyes, skin or clothing. If acid splashes in eyes or on skin, flush the contaminated area immediately with large quantities of water. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: - a 12 Volt battery charger with a minimum 30 Amp rating is the only type recommended to use when charging the high voltage battery. - depending on the condition of the second running vehicles alternator and the number of accessories operating on both vehicles, it could take up to 60 minutes to charge the high voltage battery. To minimize the charging time make sure that the minimum amount of accessories are being used. WARNING: Always wear eye protection and remove all metal jewelry such as watch bands or bracelets which might make an unintended electrical contact. Failure to follow these instructions may result in possible serious or fatal injury. 1. Turn off all unnecessary electrical loads such as the heater, radio, lights etc. 2. Set the parking brake, place the transmission in PARK and turn the ignition to the ON/RUN position. 3. Place the battery charger within cable reach of the remote battery posts located under the hood. 4. Connect the positive cable clamp of the 12 Volt battery charger to the remote positive post located near the engine oil dipstick underhood. 5. Connect the negative cable clamp of the 12 Volt battery charger to the remote negative post located near the driver side fender underhood. WARNING: During cold weather when temperatures are below freezing point, electrolyte in a discharged battery may freeze. Do not attempt jump-starting because the battery could rupture or explode. The battery temperature must be brought up above freezing point before attempting a jump-start. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service and Repair > Page 6021 6. Place the 12 Volt battery charger to a medium setting and turn ON the battery charger to allow the high voltage battery to charge. CAUTION: Using a setting higher then a medium rate of charge could damage the 12 Volt battery. 7. If the 12 Volt battery charger has been properly connected and the system determines that the conditions are correct for charging, the navigation radio displays a message "CHARGING in Progress". NOTE: To minimize the charging time, it is recommended to leave the key in the OFF position while in the "CHARGING in Progress" mode, however the key may be turned to the ON/RUN position to use an accessory. Allow the system to charge until the navigation radio displays the "Attempt to start vehicle" message. 8. Attempt to start the vehicle, if the vehicle starts, leave it running and turn off the 12 Volt battery charger. 9. Remove the 12 Volt battery charger negative clamp. CAUTION: Be careful of the moving belt and fan blades. 10. Remove the 12 Volt battery charger positive clamp. WARNING: Any procedure other than above could result in: - personal injury caused by electrolyte squirting out the battery vent. - personal injury or property damage due to battery explosion. - damage to charging system or immobilized vehicle. Failure to follow these instructions may result in possible serious or fatal injury. Charging Aborted Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service and Repair > Page 6022 If the "Jump Assist" procedure is interrupted, the navigation radio displays "Charge Aborted". "Jump Assist" can be aborted by the following items: - the key is turned to the START position while the system is being charged. - incorrect installation of the 12 Volt battery charger. - poor cable clamp contact. - the Hybrid Control Module determines conditions are not suitable for charging. If the "Charge Aborted" message is displayed check the battery charger clamps, make sure there is a good connection. Check to see that the 12 Volt battery charger is turned on. Turn off the ignition, wait 10 to 15 seconds and turn the key to the START position. If the "Charge Aborted" message is still active have the vehicle towed to the nearest authorized dealer for service. Jump-Starting - 12 Volt Battery Jumper Cable Clamp Connections WARNING: - battery fluid is a corrosive acid solution; do not allow battery fluid to contact eyes, skin or clothing. Don't lean over battery when attaching clamps or allow the clamps to touch each other. If acid splashes in eyes or on skin, flush the contaminated area immediately with large quantities of water. a battery generates hydrogen gas which is flammable and explosive. Keep flame or spark away from the vent holes. Do not use Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service and Repair > Page 6023 a booster battery or any other booster source with an output that exceeds 12 Volts. Failure to follow these instructions may result in possible serious or fatal injury. Check the Battery Test Indicator (if equipped). If a light or bright colored dot is visible in the indicator (if equipped), Do Not jump-start the battery. If the indicator (if equipped) is dark or shows a green dot, proceed as follows: 1. Wear eye protection and remove all metal jewelry such as watch bands or bracelets which might make an unintended electrical contact. 2. Park the booster vehicle within cable reach but without letting the vehicles touch. Set the parking brake, place the automatic transmission in PARK and turn the ignition off on both vehicles. 3. Turn off heater, radio and all unnecessary electrical loads. 4. Connect one end of a jumper cable (4) to the positive terminal (5) of the booster battery. 5. Connect the other end of the same cable to the remote positive post. WARNING: Do not permit vehicles to touch each other as this could establish a ground connection and personal injury could result. Failure to follow these instructions may result in possible serious or fatal injury. 6. Connect the other cable, first to the negative terminal of the booster battery then to the engine of the vehicle with the discharged battery. Make sure you have a good contact on the engine. WARNING: Do not connect the cable to the negative post of the discharge battery. The resulting electrical spark could cause the battery to explode. During cold weather when temperatures are below freezing point, electrolyte in a discharged battery may freeze. Do not attempt jump-starting because the battery could rupture or explode. The battery temperature must be brought up above freezing point before attempting a jump-start. Failure to follow these instructions may result in possible serious or fatal injury. 7. Start the engine in the vehicle which has the booster battery, let the engine idle a few minutes, then start the engine in the vehicle with the discharged battery. 8. When removing the jumper cables, reverse the above sequence exactly. Be careful of the moving belts and fan. WARNING: Any procedure other than above could result in: - personal injury caused by electrolyte squirting out the battery vent. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service and Repair > Page 6024 - personal injury or property damage due to battery explosion. - damage to charging system of booster vehicle or of immobilized vehicle. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Battery Cables - Description Battery Cable: Description and Operation Battery Cables - Description DESCRIPTION The battery cables are large gauge, stranded copper wires sheathed within a heavy plastic or synthetic rubber insulating jacket. The wire used in the battery cables combines excellent flexibility and reliability with high electrical current carrying capacity. The battery cables cannot be repaired. If damaged or inoperative, they must be replaced. The battery cables feature a stamped brass clamping type female battery terminal crimped onto one end of the battery cable wire, that is solder-dipped. A square headed pinch-bolt and hex nut are installed at the open end of the female battery terminal clamp. The battery positive cable also includes a red molded rubber protective cover for the female battery terminal clamp. Large eyelet type terminals are crimped onto the opposite end of the battery cable wire and then solder-dipped. The battery positive cable wires have a red insulating jacket to provide visual identification and feature a larger female battery terminal clamp to allow connection to the larger battery positive terminal post. The battery negative cable wires have a black insulating jacket and a smaller female battery terminal clamp. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Battery Cables - Description > Page 6029 Battery Cable: Description and Operation Battery Cables - Operation OPERATION The battery cables connect the battery terminal posts to the vehicle electrical system. These cables also provide a return path for electrical current generated by the charging system for restoring the voltage potential of the battery. The female battery terminal clamps on the ends of the battery cable wires provide a strong and reliable connection of the battery cable to the battery terminal posts. The terminal pinch bolts allow the female terminal clamps to be tightened around the male terminal posts on the top of the battery. The eyelet terminals secured to the ends of the battery cable wires opposite the female battery terminal clamps provide secure and reliable connection of the battery to the vehicle electrical system. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 6030 Battery Cable: Testing and Inspection BATTERY CABLES A voltage drop test will determine if there is excessive resistance in the battery cable terminal connections or the battery cables. If excessive resistance is found in the battery cable connections, the connection point should be disassembled, cleaned of all corrosion or foreign material, then reassembled. Following reassembly, check the voltage drop for the battery cable connection and the battery cable again to confirm repair. When performing the voltage drop test, it is important to remember that the voltage drop is giving an indication of the resistance between the two points at which the voltmeter probes are attached. EXAMPLE: When testing the resistance of the battery positive cable, touch the voltmeter leads to the battery positive cable terminal clamp and to the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud. If you probe the battery positive terminal post and the battery positive cable eyelet terminal at the starter solenoid B(+) terminal stud, you are reading the combined voltage drop in the battery positive cable terminal clamp-to-terminal post connection and the battery positive cable. TESTING VOLTAGE DROP TEST WARNING: If the battery shows signs of freezing, leaking, loose posts, or low electrolyte level, do not test, assist-boost, or charge. The battery may arc internally and explode. Personal injury and/or vehicle damage may result. WARNING: Explosive hydrogen gas forms in and around the battery. Do not smoke, use flame, or create sparks near the battery. Personal injury and/or vehicle damage may result. WARNING: The battery contains sulfuric acid, which is poisonous and caustic. Avoid contact with the skin, eyes, or clothing. In the event of contact, flush with water and call a physician immediately. Keep out of the reach of children. WARNING: If the battery is equipped with removable cell caps, be certain that each of the cell caps is in place and tight before the battery is returned to service. Personal injury and/or vehicle damage may result from loose or missing cell caps. The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing this test, be certain that the following procedures are accomplished: - The battery is fully-charged and tested. - Fully engage the parking brake. - If the vehicle is equipped with an automatic transmission, place the gearshift selector lever in the Park position. If the vehicle is equipped with a manual transmission, place the gearshift selector lever in the Neutral position and block the clutch pedal in the fully depressed position. - Verify that all lamps and accessories are turned off. - To prevent the engine from starting, remove the proper fuse in the PDC. 1. Connect the positive lead of the voltmeter (1) to the battery negative terminal post. Connect the negative lead of the voltmeter (1) to the battery negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Description and Operation > Page 6031 2. Connect the positive lead of the voltmeter (1) to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. 3. Connect the voltmeter (2) to measure between the battery positive cable terminal clamp (1) and the starter solenoid (3) B(+) terminal stud. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid B(+) terminal stud. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery positive cable. 4. Connect the voltmeter (1) to measure between the battery (2) negative cable terminal clamp and a good clean ground (3) on the engine block. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Tray - Removal Battery Tray: Service and Repair Battery Tray - Removal REMOVAL 1. Remove the battery from the battery tray, See: Service and Repair/Removal and Replacement/Battery - Removal. 2. Remove the two upper bolts for the battery tray (1). 3. Remove the right front tire and wheel assembly See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. 4. Remove the right front wheelhouse splash shield See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation. 5. Remove the lower battery tray (1) mounting bolts (2). 6. Remove the electrical routing clips at the battery tray. 7. Remove the battery tray (1) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Battery Tray > Component Information > Service and Repair > Battery Tray - Removal > Page 6036 Battery Tray: Service and Repair Battery Tray - Installation INSTALLATION 1. Clean and inspect the battery tray (1), See: Service and Repair/Procedures/Battery Cleaning and Inspection. 2. Position the battery tray (1) into the vehicle. 3. Install and tighten the lower bolts (2) that secure the battery tray (1). Tighten the screws to 12.4 Nm (110 in. lbs.). 4. Install the right front wheelhouse splash shield. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation 5. Install the right front tire and wheel assembly See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. 6. Install and tighten upper bolts that secure the battery tray to fender frame. Tighten the screws to 12.4 Nm (110 in. lbs.). 7. Install the battery onto the battery tray See: Service and Repair/Removal and Replacement/Battery - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Remote Battery Jumper Terminal > Component Information > Locations Remote Battery Jumper Terminal: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Remote Battery Jumper Terminal > Component Information > Locations > Page 6040 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Remote Battery Jumper Terminal > Component Information > Diagrams > Remote Jump Post (HEV) (Headlamp And Dash Side) 1 Way Remote Battery Jumper Terminal: Diagrams Remote Jump Post (HEV) (Headlamp And Dash Side) 1 Way Connector (HEV) - (HEADLAMP AND DASH SIDE) 1 WAY POST-REMOTE JUMP (HEV) - (HEADLAMP AND DASH SIDE) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Battery > Remote Battery Jumper Terminal > Component Information > Diagrams > Remote Jump Post (HEV) (Headlamp And Dash Side) 1 Way > Page 6043 Remote Battery Jumper Terminal: Diagrams Remote Jump Post (HEV) (Battery) 2 Way Connector (HEV) - (BATTERY) 2 WAY POST-REMOTE JUMP (HEV) - (BATTERY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications Alternator: Specifications GENERATOR RATINGS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 6048 Alternator: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications > Page 6049 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Generator (Battery) 1 Way Alternator: Diagrams Generator (Battery) 1 Way Connector - (BATTERY) 1 WAY GENERATOR - (BATTERY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Generator (Battery) 1 Way > Page 6052 Alternator: Diagrams Generator 2 Way Connector - (ENGINE) 2 WAY GENERATOR - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Description and Operation > Generator - Description Alternator: Description and Operation Generator - Description HEV The charging system is a intrigual part of the Hybrid Electrical Vehicle (HEV) system. The Electrically Variable (EV) transmissions e-motor A, is responsible for the charging for the 12V and 300V system through regenerative braking. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Description and Operation > Generator - Description > Page 6055 Alternator: Description and Operation Generator - Operation HEV Regenerative braking is used in place of the alternator to charge the 300V system. The regenerative braking system is used to recover kinetic energy into the High Voltage (HV) battery when the vehicle slows or brakes. The regenerative braking occurs almost anytime the driver uses the brakes or coasts at speeds above 6 MPH. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal Alternator: Service and Repair Generator - Removal REMOVAL CAUTION: Disconnect the negative battery cable before removing the battery output wire from generator. Failure to do so can result in injury or damage to electrical system. 1. Disconnect the negative battery cable (1). CAUTION: Do not let the tensioner arm snap back to the free arm position, severe damage may occur to the tensioner. 2. Insert a suitable square drive ratchet into the square hole on the belt tensioner arm (7). 3. Release the belt tension by rotating the tensioner (7) clockwise until the accessory drive belt (4) can be removed from the generator pulley only See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal > Page 6058 4. Unsnap the plastic insulator cap from the B+ output terminal (1). 5. Remove the B+ terminal retaining nut (2) and disconnect the B+ terminal eyelet from the generator output stud. 6. Disconnect the field wire electrical connector (3) by pushing on the connector tab. 7. Remove the generator support bracket nuts and bolt (3,4) and remove the support bracket (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal > Page 6059 8. Remove the two generator mounting bolts (1,3) and the generator (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal > Page 6060 Alternator: Service and Repair Generator - Installation INSTALLATION 1. Position the generator (2) into the mounting bracket and install the two retaining bolts (1,3) and tighten the bolts to 41 Nm (30 ft. lbs.). 2. Install the support bracket (2) to the front of the generator and install the bolt and nuts (3) and tighten the bolt and nuts to 41 Nm (30 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal > Page 6061 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator - Removal > Page 6062 ERROR: stackunderflow OFFENDING COMMAND: ~ STACK: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation > Voltage Regulator - Description Voltage Regulator: Description and Operation Voltage Regulator - Description DESCRIPTION The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a voltage regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced separately. If replacement is necessary, the PCM must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation > Voltage Regulator - Description > Page 6067 Voltage Regulator: Description and Operation Voltage Regulator - Operation OPERATION The amount of DC current produced by the generator is controlled by EVR circuitry contained within the PCM. This circuitry is connected in series with the second rotor field terminal and the generator ground. Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field. The EVR circuitry monitors system line voltage (B+). It then determines a target charging voltage. If sensed battery voltage is 0.5 volts or lower than the target voltage, the PCM uses Pulse Width Modulation (PWM) to ground the field winding until sensed battery voltage is 0.5 volts above target voltage. A circuit in the PCM cycles the ground side of the generator field up to 100 times per second (100Hz), but has the capability to ground the field control wire 100% of the time (full field) to achieve the target voltage. If the charging rate cannot be monitored (limp-in), a duty cycle of 25% is used by the PCM in order to have some generator output. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Removal REMOVAL 1. Disconnect negative cable from battery. 2. Remove the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Removal. 3. Remove the tilt lever handle. 4. Remove the lower shroud (2) from steering column. 5. Place shifter in PARK position. The ignition key (2) must be in the key cylinder (1) for cylinder removal. 6. A retaining pin is located at side of key cylinder assembly. a. Rotate key (2) to RUN position. b. Press in on retaining pin with a small punch (3) , while pulling key cylinder (1) from ignition switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 6074 7. Remove the key (2) and key cylinder (1) from the column (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Removal > Page 6075 Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Installation INSTALLATION The ignition key (2) must be in the key cylinder (1) for cylinder installation. 1. Install the key cylinder (1) into the housing (3) using care to align the end of the key cylinder with the ignition switch. 2. Push the key cylinder (1) in until it clicks. 3. Replace the lower shroud. 4. Install the tilt lever handle. 5. Install the steering column opening cover See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Steering Column Opening Cover - Installation. 6. Reconnect the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Antenna > Component Information > Description and Operation Keyless Start Antenna: Description and Operation DESCRIPTION The Remote Start Antenna Module Assembly consists of an electrical connection to the WCM/SKREEM (1), a length of coax cable (2), two mounting clips (3) and (4), and a control module/antenna (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal Keyless Start Antenna: Service and Repair Remote Start Antenna - Removal REMOVAL The Remote Start Antenna Module Assembly consists of an electrical connection to the WCM/SKREEM (1), a length of coax cable (2), two mounting clips (3) and (4), and a control module/antenna (5). The control module (3) is located under the instrument panel cover (2). The module electrical connector plugs into the WCM/SKREEM at the right side of the steering column. 1. Disconnect and isolate negative battery cable. 2. Remove steering column trim panel (knee blocker). 3. Remove steering column shrouds. 4. Remove left instrument panel (IP) end cap. 5. Remove IP cluster bezel. 6. Remove IP cluster and its three connectors. 7. Remove left A-pillar trim. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 6082 8. Unclip upper IP bezel (defroster). 9. Remove two module mounting screws (4) from module (3). 10. Disconnect coax cable retainers (3) and (4) from IP. 11. Remove two WCM/SKREEM mounting screws at steering column (1). 12. Remove WCM/SKREEM from steering column (1). 13. Disconnect coax cable electrical connector (2) at WCM/SKREEM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 6083 14. Remove module (2) from top of instrument panel while fishing coax cable (1) through openings. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 6084 Keyless Start Antenna: Service and Repair Remote Start Antenna - Installation INSTALLATION The Remote Start Antenna Module Assembly consists of an electrical connection to the WCM/SKREEM (1), a length of coax cable (2), two mounting clips (3) and (4), and a control module/antenna (5). 1. Fish coax cable (1) through openings on top of instrument panel. Position module (2) to top of instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 6085 2. Install two module mounting screws (4) to module (3). 3. Connect coax cable retainers (3) and (4) to instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 6086 4. Connect coax cable electrical connector (2) to WCM/SKREEM. 5. Install WCM/SKREEM to steering column (1). 6. Clip upper instrument panel (IP) bezel (defroster). 7. Install left A-pillar trim. 8. Install IP cluster and its three connectors. 9. Install IP cluster bezel. 10. Install left IP end cap. 11. Install steering column trim panel (knee blocker). 12. Install steering column shrouds. 13. Connect negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications Starter Motor: Specifications STARTING SYSTEM Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6090 Starter Motor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Specifications > Page 6091 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Starter (Engine) 1 Way Starter Motor: Diagrams Starter (Engine) 1 Way Connector - (ENGINE) 1 WAY STARTER - (ENGINE) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Starter (Engine) 1 Way > Page 6094 Starter Motor: Diagrams Starter (Battery) 1 Way Connector - (BATTERY) 1 WAY STARTER - (BATTERY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 6095 Starter Motor: Testing and Inspection STARTER MOTOR NOTE: This test can only be performed with starter motor removed from vehicle. Correct starter motor operation can be confirmed by performing the following free running bench test. Refer to Specifications for starter motor specifications. 1. Remove starter motor from vehicle. Refer to Starter Motor Removal and Installation. 2. Mount starter motor securely in a soft-jawed bench vise. The vise jaws should be clamped on the mounting flange of starter motor. Never clamp on starter motor by field frame. 3. Connect a suitable volt-ampere tester and a 12-volt battery to starter motor in series, and set ammeter to 100 ampere scale. See instructions provided by manufacturer of volt-ampere tester being used. 4. Install jumper wire from solenoid terminal to solenoid battery terminal. The starter motor should operate. If starter motor fails to operate, replace faulty starter motor assembly. 5. Adjust carbon pile load of tester to obtain free running test voltage. Refer to Specifications for starter motor free running test voltage specifications. 6. Note reading on ammeter and compare reading to free running test maximum amperage draw. Refer to Specifications for starter motor free running test maximum amperage draw specifications. 7. If ammeter reading exceeds maximum amperage draw specification, replace faulty starter motor assembly. STARTER SOLENOID NOTE: Certain vehicles with certain engines may require starter motor removal for the following test. 1. If necessary, remove starter motor from vehicle. Refer to Starter Motor Removal and Installation. 2. Disconnect solenoid connector wiring from starter motor. 3. Check for continuity between solenoid terminal (2) and solenoid case (3). There should be continuity. If not OK, replace faulty starter motor assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter - Removal Starter Motor: Service and Repair Starter - Removal REMOVAL 3.7L / 4.7L 1. Disconnect and isolate negative battery cable. 2. Raise and support vehicle. 3. Note: If equipped with 4WD and certain transmissions, a support bracket is used between front axle and side of transmission. Remove 2 support bracket bolts at transmission. Pry support bracket slightly to gain access to lower starter mounting bolt. 4. Remove two bolts (3) if equipped with an automatic transmission. 5. Move starter motor (4) towards front of vehicle far enough for nose of starter pinion housing to clear housing. Always support starter motor during this process, do not let starter motor hang from wire harness. 6. Tilt nose downwards and lower starter motor far enough to access and remove nut (2) that secures battery positive cable wire harness connector eyelet (1) to solenoid battery terminal stud. Do not let starter motor hang from wire harness. 7. Remove battery positive cable wire harness connector eyelet (5) from solenoid battery terminal stud. 8. Disconnect battery positive cable wire harness connector from solenoid terminal connector receptacle. 9. Remove starter motor. 5.7L V-8 1. Disconnect and isolate negative battery cable. 2. Raise and support vehicle. 3. Note: If equipped with 4WD and certain transmissions, a support bracket is used between front axle and side of transmission. Remove 2 support bracket bolts at transmission. Pry support bracket slightly to gain access to lower starter mounting bolt. 4. Remove two mounting bolts (2). 5. Move starter motor towards front of vehicle far enough for nose of starter pinion housing to clear housing. Always support starter motor (1) during this process, do not let starter motor hang from wire harness. 6. Tilt nose downwards and lower starter motor far enough to access and remove nut that secures battery positive cable wire harness connector eyelet to solenoid battery terminal stud. Do not let starter motor hang from wire harness. 7. Remove battery positive cable wire harness connector eyelet from solenoid battery terminal stud. 8. Disconnect battery positive cable wire harness connector from solenoid terminal connector receptacle. 9. Remove starter motor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter - Removal > Page 6098 Starter Motor: Service and Repair Starter - Installation INSTALLATION 3.7L / 4.7L With Manual Trans. 1. Connect solenoid wire to starter motor (snaps on). 2. Position battery cable (1) to solenoid stud. Install and tighten battery cable eyelet nut (2) to 25 Nm (19 ft. lbs.). Do not allow starter motor to hang from wire harness. 3. Position starter motor (5) to transmission. 4. Install the lockwasher (6), nut (8) and bolt (9). Tighten the nut (8) to 68 Nm (50 ft. lbs.). 5. Lower vehicle. 6. Connect negative battery cable. 3.7L / 4.7L With Auto. Trans. 1. Connect solenoid wire to starter motor (snaps on). 2. Position battery cable (1) to solenoid stud. Install and tighten battery cable eyelet nut (2) to 25 Nm (19 ft. lbs.). Do not allow starter motor to hang from wire harness. 3. Position starter motor (4) to transmission. 4. If equipped with automatic transmission, slide cooler tube bracket into position. 5. Install and tighten both bolts (3) to 68 Nm (50 ft. lbs.). 6. Lower vehicle. 7. Connect negative battery cable. 5.7L V-8 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Service and Repair > Starter - Removal > Page 6099 1. Connect solenoid wire to starter motor (snaps on). 2. Position battery cable to solenoid stud. Install and tighten battery cable eyelet nut to 25 Nm (19 ft. lbs.). Do not allow starter motor to hang from wire harness. 3. Position starter motor (1) to engine. 4. If equipped with automatic transmission, slide cooler tube bracket into position. 5. Install and tighten both mounting bolts (2) to 68 Nm (50 ft. lbs.). 6. Lower vehicle. 7. Connect negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Starter Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations > Page 6103 Starter Relay: Diagrams Connector (IN PDC) RELAY-STARTER MOTOR (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Description and Operation > Starter Relay - Description Starter Relay: Description and Operation Starter Relay - Description DESCRIPTION The starter relay is an electromechanical device that switches battery current to the pull-in coil of the starter solenoid when the ignition switch is turned to the Start position. The starter relay is located in the Power Distribution Center (PDC) in the engine compartment. See the power distribution center cover for relay identification and location. The starter relay is a International Standards Organization (ISO) relay. Relays conforming to ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. The starter relay cannot be repaired or adjusted. If faulty or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Description and Operation > Starter Relay - Description > Page 6106 Starter Relay: Description and Operation Starter Relay - Operation OPERATION The ISO relay consists of an electromagnetic coil, a resistor or diode, and three (two fixed and one movable) electrical contacts. The movable (common feed) relay contact is held against one of the fixed contacts (normally closed) by spring pressure. When electromagnetic coil is energized, it draws the movable contact away from normally closed fixed contact, and holds it against the other (normally open) fixed contact. When electromagnetic coil is de-energized, spring pressure returns movable contact to normally closed position. The resistor or diode is connected in parallel with electromagnetic coil within relay, and helps to dissipate voltage spikes produced when coil is de-energized. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Service and Repair > Starter Relay - Removal Starter Relay: Service and Repair Starter Relay - Removal REMOVAL The starter relay is located in the Power Distribution Center (PDC). Refer to label on PDC cover for relay location. 1. Disconnect and isolate negative battery cable. 2. Remove cover from Power Distribution Center (PDC) for relay identification and location. 3. Remove starter relay from PDC. 4. Check condition of relay terminals and PDC connector terminals for damage or corrosion. Repair if necessary before installing relay. 5. Check for pin height (pin height should be the same for all terminals within the PDC connector). Repair if necessary before installing relay. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Service and Repair > Starter Relay - Removal > Page 6109 Starter Relay: Service and Repair Starter Relay - Installation INSTALLATION 1. Push down firmly on starter relay until terminals are fully seated into PDC receptacle. 2. Install PDC cover. 3. Connect battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Console Power Outlet Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Console Power Outlet > Page 6115 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Console Power Outlet > Page 6116 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6119 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6120 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6121 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6122 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6123 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6124 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6125 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6126 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6127 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6128 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6129 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6130 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6131 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6132 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6133 Auxiliary Power Outlet: Connector Views AC Power Outlet (Center Console) 6 Way Connector - (CENTER CONSOLE) 6 WAY POWER OUTLET-AC - (CENTER CONSOLE) 6 WAY Console Power Outlet (Center Console) 3 Way Connector - (CENTER CONSOLE) 3 WAY POWER OUTLET-CONSOLE - (CENTER CONSOLE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6134 Instrument Panel Power Outlet (Instrument Panel) 3 Way Connector - (INSTRUMENT PANEL) 3 WAY POWER OUTLET-INSTRUMENT PANEL - (INSTRUMENT PANEL) 3 WAY Rear Power Outlet (Body) 3 Way Connector - (BODY) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6135 POWER OUTLET-REAR - (BODY) 3 WAY Rear Seat Power Outlet (Rear Seat) 3 Way Connector - (REAR SEAT) 3 WAY POWER OUTLET-REAR SEAT - (REAR SEAT) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6136 Auxiliary Power Outlet: Electrical Diagrams HORN/CIGAR LIGHTER/POWER OUTLET - Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6137 Horn/Cigar Lighter/Power Outlet 8W-41-01 Horn/Cigar Lighter/Power Outlet 8W-41-02 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6138 Horn/Cigar Lighter/Power Outlet 8W-41-03 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Power Outlet - Description Auxiliary Power Outlet: Description and Operation Power Outlet - Description DESCRIPTION INSTRUMENT PANEL MOUNTED An instrument panel mounted cigar lighter/power outlet receptacle is optional equipment on this model. On models equipped with the optional Smoker's Package, the cigar lighter knob and heating element are included. On models without the Smoker's Package, the cigar lighter receptacle is equipped with a snap fit plastic cap and is treated as an auxiliary power outlet. The cigar lighter receptacle is installed in the instrument panel accessory switch bezel, which is located near the bottom of the instrument panel center stack area, below the radio. The cigar lighter base is secured by a snap fit within the center lower bezel. This power outlet has a constant 12 volt battery feed. The cigar lighter receptacle is serviced with the accessory switch bezel and if defective, the entire switch bezel must be replaced. The plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if faulty or damaged, they must be replaced. FRONT CONSOLE AND REAR CARGO MOUNTED A front console mounted power outlet is standard equipment and a rear cargo area power outlet is optional equipment on this model. The front console mounted power outlet is mounted near the front of the console just in front of the cup holders. This outlet can be used as a cigar lighter or power outlet, but only has 12 volt battery voltage when the ignition is in the ON or ACC positions. The rear power outlet is installed in the right rear quarter trim panel, near the spare tire jack. The power outlet base and mount are secured by a snap fit within the quarter trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. It has 12 volt battery voltage when the ignition is in the ON or ACC positions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Power Outlet - Description > Page 6141 Auxiliary Power Outlet: Description and Operation Power Outlet - Operation OPERATION CIGAR LIGHTER/POWER OUTLET The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. POWER OUTLET The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Totally Integrated Power Module (TIPM) through a fuse in the fuse block when the ignition is in the ON or ACC positions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > AC Power Outlet - Removal Auxiliary Power Outlet: Service and Repair AC Power Outlet - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the center console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Rear Center Console - Removal. 3. Disconnect electrical connector. 4. Remove AC power outlet. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > AC Power Outlet - Removal > Page 6144 Auxiliary Power Outlet: Service and Repair AC Power Outlet - Installation INSTALLATION 1. Connect the electrical connector. 2. Install the AC power outlet. 3. Install the center console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Installation. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > AC Power Outlet - Removal > Page 6145 Auxiliary Power Outlet: Service and Repair Power Outlet - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Look inside and note position of the retaining bosses (1). 3. Using special tool 9857 Power Outlet Remover. Insert the tool forcing the bosses out of base. 4. Pull out the base through mounting ring by gently rocking the tool (3). 5. Disconnect the base wires. 6. Set base aside and remove base mount ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > AC Power Outlet - Removal > Page 6146 Auxiliary Power Outlet: Service and Repair Power Outlet - Installation INSTALLATION 1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and the mount ring with the index tab at 9 o'clock to the key in the instrument panel. Install the ring. 2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring at the same location. 3. Push base into the bezel till it locks. 4. Install cigar lighter cap. 5. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet Switch > Component Information > Locations > Page 6150 Auxiliary Power Outlet Switch: Diagrams Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-INVERTER - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 6154 Circuit Breaker: Diagrams Connector - 2 WAY CIRCUIT BREAKER - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel Fuse: Locations Fuse Panel FUSE PANELS WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions CAUTION: When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it suggests a problem in the circuit that must be corrected. NOTE: If leaving the vehicle dormant for longer than 21 days you may want to take steps to protect the battery. To do this disconnect the battery or disconnect the two Ignition Off Draw (IOD) fuses located in the auxiliary Power Distribution Center (PDC) in the engine compartment. The IOD cavities include a snap in retainer that allows the fuses to be disconnected without removing them from the fuse block. To reconnect the IOD fuses press them back into the cavity. Underhood Fuses Integrated Power Module (IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6159 IPM MODULE An Integrated Power Module (IPM) is located in the left side of the engine compartment. This center contains cartridge fuses, mini fuses and relays. A description of each fuse and component may be stamped on the inside cover, otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart. Integrated Power Module (IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6160 HEV Power Distribution Center (PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6161 The vehicle is equipped with an electrical Power Distribution Center (PDC) located in the left side of the engine compartment. This center contains cartridge fuses, mini fuses and relays. A description of each fuse and component may be stamped on the inside cover, otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart. These fuses and relays can be obtained from your authorized dealer. HEV Power Distribution Center (PDC) - RELAYS HEV Power Distribution Center (PDC) - FUSES Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6162 HEV Power Distribution Center 2 (PDC2) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6163 HEV Power Distribution Center 2 (PDC2) Non-HEV Power Distribution Center (PDC) RELAYS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6164 FUSES Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6165 Interior Fuses Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6166 Junction Block Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6167 Fuse Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6168 The fuse block contains blade-type mini-fuses, relays, and circuit breakers for high-current circuits. It is located in the left kick panel. It is accessible through a snap-in cover. Fuse Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6169 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6170 Fuse: Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6171 Fuse: Locations Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6172 Fuse: Locations Junction Block Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6173 Fuse: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Hev Power Distribution Center (PDC) Fuse: Application and ID Hev Power Distribution Center (PDC) HEV Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6176 Fuse: Application and ID Integrated Power Module Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6177 Fuse: Application and ID Junction Block Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6178 Fuse: Application and ID Power Distribution Center Power Distribution Center W/O HEV Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Description and Operation > IOD Fuse - Description Fuse: Description and Operation IOD Fuse - Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Integrated Power Module when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the Integrated Power Module as part of the preparation procedures performed just prior to new vehicle delivery. The following circuits are protected by the IOD fuse: - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps - Radio - Underhood Lamp Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Description and Operation > IOD Fuse - Description > Page 6181 Fuse: Description and Operation IOD Fuse - Operation OPERATION The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed. The IOD fuse is disconnected from Integrated Power Module when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Junction Block Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 6186 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 6187 Fuse Block: Connector Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 6188 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 6189 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 6190 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6193 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6194 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6195 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6196 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6197 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6198 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6199 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6200 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6201 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6202 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6203 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6204 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6205 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6206 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6207 Fuse Block: Connector Views Junction Block C1 (Headlamp And Dash) Connector C1 - (HEADLAMP AND DASH) JUNCTION BLOCK - (HEADLAMP AND DASH) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6208 Junction Block C2 (Instrument Panel Side) Connector C2 - (INSTRUMENT PANEL SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6209 JUNCTION BLOCK - (INSTRUMENT PANEL SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6210 Junction Block C3 (Body Side) Connector C3 - (BODY SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6211 JUNCTION BLOCK - (BODY SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6212 Junction Block C4 (Instrument Panel Side) Connector C4 - (INSTRUMENT PANEL SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6213 JUNCTION BLOCK - (INSTRUMENT PANEL SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6214 Junction Block C5 (Headlamp And Dash) Connector C5 - (HEADLAMP AND DASH) JUNCTION BLOCK - (HEADLAMP AND DASH) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6215 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Hev Power Distribution Center (PDC) Fuse Block: Application and ID Hev Power Distribution Center (PDC) HEV Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6218 Fuse Block: Application and ID Integrated Power Module Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6219 Fuse Block: Application and ID Junction Block Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6220 Fuse Block: Application and ID Power Distribution Center Power Distribution Center W/O HEV Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Power Distribution Center (PDC) - Description Fuse Block: Description and Operation Power Distribution Center (PDC) - Description DESCRIPTION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) is located next to the Power Distribution Center (PDC) (3) in the engine compartment. The HEV PDC (4) works with the Front Control Module (FCM) (1), the Integrated Power Module (IPM) (2) and the PDC (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 6223 Fuse Block: Description and Operation Power Distribution Center (PDC) - Operation OPERATION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) provides the extra power needed for the Hybrid Electric Vehicle (HEV). The HEV PDC provides power to: - Transmission Auxiliary Pump (TPCM) - Electric Vacuum Pump - Electric High Voltage Power Steering (EHPS) - Solid State Relay Electric Vacuum Pump The HEV PDC is serviced as part of the engine compartment body harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 6224 Fuse Block: Description and Operation Junction Block - Description DESCRIPTION An electrical Junction Block (JB) (1) is concealed behind the left outboard end of the instrument panel cover. The JB combines the functions previously provided by a separate fuseblock module and relay center, serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as a fuse layout to help ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 6225 Fuse Block: Description and Operation Junction Block - Operation OPERATION All of the circuits entering and leaving the JB do so through wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal Fuse Block: Service and Repair Power Distribution Center (PDC) - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Depress retaining tabs on the side on the PDC (1). 3. Disconnect electrical harness connectors (2) and remove PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 6228 Fuse Block: Service and Repair Power Distribution Center (PDC) - Installation INSTALLATION 1. Connect electrical harness connectors to Power Distribution Center (PDC). 2. Position PDC and engage into the retaining tabs. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 6229 Fuse Block: Service and Repair Junction Block - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left cowl trim cover. 3. Remove the mounting fasteners (3). 4. Disconnect the electrical harness connectors and remove Junction Block (1). 5. Transfer components as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 6230 Fuse Block: Service and Repair Junction Block - Installation INSTALLATION 1. Connect wire harness connectors to the Junction Block (JB) (1). 2. Position JB and install mounting fasteners (3). 3. Install left cowl trim cover). 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-014-09 > Sep > 09 > EVIC Module - Intermittent Or No Operation Power Distribution Module: Customer Interest EVIC Module - Intermittent Or No Operation NUMBER: 08-014-09 GROUP: Electrical DATE: September 3, 2009 SUBJECT: EVIC Module Intermittent or No Operation OVERVIEW: This bulletin involves inspecting the Satellite Antenna for looseness when making EVIC module repairs. MODELS: 2009 (HB) Durango (Includes Hybrid) 2009 (HG) Aspen (Includes Hybrid) SYMPTOM/CONDITION: The EVIC may intermittently operate or stop functioning. DISCUSSION: Before replacing the EVIC module, inspect the Satellite Antenna for looseness or for signs of water intrusion from around the antenna base. If looseness is found tighten the antenna before replacing the EVIC module. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-014-09 > Sep > 09 > EVIC Module - Intermittent Or No Operation Power Distribution Module: All Technical Service Bulletins EVIC Module - Intermittent Or No Operation NUMBER: 08-014-09 GROUP: Electrical DATE: September 3, 2009 SUBJECT: EVIC Module Intermittent or No Operation OVERVIEW: This bulletin involves inspecting the Satellite Antenna for looseness when making EVIC module repairs. MODELS: 2009 (HB) Durango (Includes Hybrid) 2009 (HG) Aspen (Includes Hybrid) SYMPTOM/CONDITION: The EVIC may intermittently operate or stop functioning. DISCUSSION: Before replacing the EVIC module, inspect the Satellite Antenna for looseness or for signs of water intrusion from around the antenna base. If looseness is found tighten the antenna before replacing the EVIC module. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center > Page 6249 Power Distribution Module: Locations Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center > Page 6250 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center > Page 6251 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way Power Distribution Module: Diagrams 110v Inverter Module (Right Seat) 9 Way Connector - (RIGHT SEAT) 9 WAY MODULE-110V INVERTER - (RIGHT SEAT) 9 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6254 Power Distribution Module: Diagrams Integrated Power Module C1 (Headlamp And Dash) 40 Way Connector C1 - (HEADLAMP AND DASH) 40 WAY MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6255 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6256 Power Distribution Module: Diagrams Integrated Power Module C2 (Headlamp And Dash) 40 Way Connector C2 - (HEADLAMP AND DASH) 40 WAY MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6257 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6258 Power Distribution Module: Diagrams Integrated Power Module C3 (Battery) 1 Way Connector C3 - (BATTERY) 1 WAY MODULE-INTEGRATED POWER - (BATTERY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6259 Power Distribution Module: Diagrams 110v Inverter Module (Right Seat) 9 Way Connector - (RIGHT SEAT) 9 WAY MODULE-110V INVERTER - (RIGHT SEAT) 9 WAY Integrated Power Module C1 (Headlamp And Dash) 40 Way Connector C1 - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6260 MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6261 Integrated Power Module C2 (Headlamp And Dash) 40 Way Connector C2 - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6262 MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6263 Integrated Power Module C3 (Battery) 1 Way Connector C3 - (BATTERY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6264 MODULE-INTEGRATED POWER - (BATTERY) 1 WAY Power Distribution Center (Battery) 1 Way Connector (BATTERY) - 1 WAY POWER DISTRIBUTION CENTER (BATTERY) - 1 WAY Power Distribution Center C1 (Hard Wired) 20 Way Connector C1 - (HARD WIRED) 20 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6265 POWER DISTRIBUTION CENTER - (HARD WIRED) 20 WAY Power Distribution Center C2 (Hard Wired) 14 Way Connector C2 - (HARD WIRED) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6266 POWER DISTRIBUTION CENTER - (HARD WIRED) 14 WAY Power Distribution Center C3 (Hard Wired) 41 Way Connector C3 - (HARD WIRED) 41 WAY POWER DISTRIBUTION CENTER - (HARD WIRED) 41 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6267 Power Distribution Center C4 (Hard Wired) 15 Way Connector C4 - (HARD WIRED) 15 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6268 POWER DISTRIBUTION CENTER - (HARD WIRED) 15 WAY Power Distribution Center C5 (Hard Wired) 15 Way Connector C5 - (HARD WIRED) 15 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6269 POWER DISTRIBUTION CENTER - (HARD WIRED) 15 WAY Power Distribution Center C6 (HEV) (Hard Wired) 11 Way Connector C6 (HEV) - (HARD WIRED) 11 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6270 POWER DISTRIBUTION CENTER (HEV) - (HARD WIRED) 11 WAY Power Distribution Center C7 (HEV) (Hard Wired) 22 Way Connector C7 (HEV) - (HARD WIRED) 22 WAY POWER DISTRIBUTION CENTER (HEV) - (HARD WIRED) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6271 HEV Power Distribution Center (HEV) (In PDC) Connector (HEV) - (IN PDC) FUSE 2 (HEV) - (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module (IPM) - Description Power Distribution Module: Description and Operation Integrated Power Module (IPM) - Description DESCRIPTION The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The IPM is located in the engine compartment, next to the battery. The power distribution center mates directly with the (FCM) to form the IPM. The (PDC) is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module (IPM) - Description > Page 6274 Power Distribution Module: Description and Operation Integrated Power Module (IPM) - Operation OPERATION All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal Power Distribution Module: Service and Repair Integrated Power Module (IPM) - Removal REMOVAL 1. Disconnect the negative and positive battery cables. 2. Unsnap cover and remove the B+ terminal nut from the integrated power module (IPM). Remove the B+ cable. 3. Remove the IPM from the retaining bracket (1). 4. Disconnect the connectors from the (IPM). 5. Remove the Front Control Module (FCM) (2) retaining screws. 6. Disconnect the front control module by pulling it straight off the integrated power module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal > Page 6277 Power Distribution Module: Service and Repair Integrated Power Module (IPM) - Installation INSTALLATION 1. Install the Front Control Module (FCM) (2) to the Integrated Power Module (IPM). 2. Connect the electrical connectors to the IPM (1). 3. Install the IPM to the retaining bracket. 4. Install the B+ cable and nut on the IPM B+ terminal. Snap the cover in place. 5. Connect the negative and positive battery cables. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal > Page 6278 Power Distribution Module: Service and Repair Power Inverter Module - Removal REMOVAL 1. Position the passenger front seat all the way back toward the rear of the vehicle. 2. Disconnect the power inverter electrical connector (1). 3. Remove the two mounting screws (2). 4. Position the front passenger seat all the way forward to gain access to the rear of the power inverter (2). 5. Remove the two rear mounting screws (1). 6. Remove the power inverter (2) by sliding it toward the driver seat. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal > Page 6279 Power Distribution Module: Service and Repair Power Inverter Module - Installation INSTALLATION 1. Install the power inverter (2) by sliding it toward the passenger door. 2. Install the two rear mounting screws (1). 3. Position the passenger front seat all the way back toward the rear of the vehicle. 4. Install the two front mounting screws (2). 5. Connect the power inverter electrical connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-014-09 > Sep > 09 > EVIC Module - Intermittent Or No Operation Power Distribution Module: Customer Interest EVIC Module - Intermittent Or No Operation NUMBER: 08-014-09 GROUP: Electrical DATE: September 3, 2009 SUBJECT: EVIC Module Intermittent or No Operation OVERVIEW: This bulletin involves inspecting the Satellite Antenna for looseness when making EVIC module repairs. MODELS: 2009 (HB) Durango (Includes Hybrid) 2009 (HG) Aspen (Includes Hybrid) SYMPTOM/CONDITION: The EVIC may intermittently operate or stop functioning. DISCUSSION: Before replacing the EVIC module, inspect the Satellite Antenna for looseness or for signs of water intrusion from around the antenna base. If looseness is found tighten the antenna before replacing the EVIC module. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-014-09 > Sep > 09 > EVIC Module - Intermittent Or No Operation Power Distribution Module: All Technical Service Bulletins EVIC Module - Intermittent Or No Operation NUMBER: 08-014-09 GROUP: Electrical DATE: September 3, 2009 SUBJECT: EVIC Module Intermittent or No Operation OVERVIEW: This bulletin involves inspecting the Satellite Antenna for looseness when making EVIC module repairs. MODELS: 2009 (HB) Durango (Includes Hybrid) 2009 (HG) Aspen (Includes Hybrid) SYMPTOM/CONDITION: The EVIC may intermittently operate or stop functioning. DISCUSSION: Before replacing the EVIC module, inspect the Satellite Antenna for looseness or for signs of water intrusion from around the antenna base. If looseness is found tighten the antenna before replacing the EVIC module. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center > Page 6296 Power Distribution Module: Locations Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center > Page 6297 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center > Page 6298 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way Power Distribution Module: Diagrams 110v Inverter Module (Right Seat) 9 Way Connector - (RIGHT SEAT) 9 WAY MODULE-110V INVERTER - (RIGHT SEAT) 9 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6301 Power Distribution Module: Diagrams Integrated Power Module C1 (Headlamp And Dash) 40 Way Connector C1 - (HEADLAMP AND DASH) 40 WAY MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6302 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6303 Power Distribution Module: Diagrams Integrated Power Module C2 (Headlamp And Dash) 40 Way Connector C2 - (HEADLAMP AND DASH) 40 WAY MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6304 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6305 Power Distribution Module: Diagrams Integrated Power Module C3 (Battery) 1 Way Connector C3 - (BATTERY) 1 WAY MODULE-INTEGRATED POWER - (BATTERY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6306 Power Distribution Module: Diagrams 110v Inverter Module (Right Seat) 9 Way Connector - (RIGHT SEAT) 9 WAY MODULE-110V INVERTER - (RIGHT SEAT) 9 WAY Integrated Power Module C1 (Headlamp And Dash) 40 Way Connector C1 - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6307 MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6308 Integrated Power Module C2 (Headlamp And Dash) 40 Way Connector C2 - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6309 MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6310 Integrated Power Module C3 (Battery) 1 Way Connector C3 - (BATTERY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6311 MODULE-INTEGRATED POWER - (BATTERY) 1 WAY Power Distribution Center (Battery) 1 Way Connector (BATTERY) - 1 WAY POWER DISTRIBUTION CENTER (BATTERY) - 1 WAY Power Distribution Center C1 (Hard Wired) 20 Way Connector C1 - (HARD WIRED) 20 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6312 POWER DISTRIBUTION CENTER - (HARD WIRED) 20 WAY Power Distribution Center C2 (Hard Wired) 14 Way Connector C2 - (HARD WIRED) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6313 POWER DISTRIBUTION CENTER - (HARD WIRED) 14 WAY Power Distribution Center C3 (Hard Wired) 41 Way Connector C3 - (HARD WIRED) 41 WAY POWER DISTRIBUTION CENTER - (HARD WIRED) 41 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6314 Power Distribution Center C4 (Hard Wired) 15 Way Connector C4 - (HARD WIRED) 15 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6315 POWER DISTRIBUTION CENTER - (HARD WIRED) 15 WAY Power Distribution Center C5 (Hard Wired) 15 Way Connector C5 - (HARD WIRED) 15 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6316 POWER DISTRIBUTION CENTER - (HARD WIRED) 15 WAY Power Distribution Center C6 (HEV) (Hard Wired) 11 Way Connector C6 (HEV) - (HARD WIRED) 11 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6317 POWER DISTRIBUTION CENTER (HEV) - (HARD WIRED) 11 WAY Power Distribution Center C7 (HEV) (Hard Wired) 22 Way Connector C7 (HEV) - (HARD WIRED) 22 WAY POWER DISTRIBUTION CENTER (HEV) - (HARD WIRED) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6318 HEV Power Distribution Center (HEV) (In PDC) Connector (HEV) - (IN PDC) FUSE 2 (HEV) - (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module (IPM) - Description Power Distribution Module: Description and Operation Integrated Power Module (IPM) - Description DESCRIPTION The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The IPM is located in the engine compartment, next to the battery. The power distribution center mates directly with the (FCM) to form the IPM. The (PDC) is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module (IPM) - Description > Page 6321 Power Distribution Module: Description and Operation Integrated Power Module (IPM) - Operation OPERATION All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal Power Distribution Module: Service and Repair Integrated Power Module (IPM) - Removal REMOVAL 1. Disconnect the negative and positive battery cables. 2. Unsnap cover and remove the B+ terminal nut from the integrated power module (IPM). Remove the B+ cable. 3. Remove the IPM from the retaining bracket (1). 4. Disconnect the connectors from the (IPM). 5. Remove the Front Control Module (FCM) (2) retaining screws. 6. Disconnect the front control module by pulling it straight off the integrated power module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal > Page 6324 Power Distribution Module: Service and Repair Integrated Power Module (IPM) - Installation INSTALLATION 1. Install the Front Control Module (FCM) (2) to the Integrated Power Module (IPM). 2. Connect the electrical connectors to the IPM (1). 3. Install the IPM to the retaining bracket. 4. Install the B+ cable and nut on the IPM B+ terminal. Snap the cover in place. 5. Connect the negative and positive battery cables. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal > Page 6325 Power Distribution Module: Service and Repair Power Inverter Module - Removal REMOVAL 1. Position the passenger front seat all the way back toward the rear of the vehicle. 2. Disconnect the power inverter electrical connector (1). 3. Remove the two mounting screws (2). 4. Position the front passenger seat all the way forward to gain access to the rear of the power inverter (2). 5. Remove the two rear mounting screws (1). 6. Remove the power inverter (2) by sliding it toward the driver seat. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal > Page 6326 Power Distribution Module: Service and Repair Power Inverter Module - Installation INSTALLATION 1. Install the power inverter (2) by sliding it toward the passenger door. 2. Install the two rear mounting screws (1). 3. Position the passenger front seat all the way back toward the rear of the vehicle. 4. Install the two front mounting screws (2). 5. Connect the power inverter electrical connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) Relay Box: Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6331 Relay Box: Locations Remote Run Relay Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6332 Relay Box: Locations Run/Start Relay Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6333 Relay Box: Locations Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6334 Relay Box: Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Remote Run Relay Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6335 Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Run/Start Relay Run Remote Relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6336 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Junction Block Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay-Run Remote Relay Box: Diagrams Relay-Run Remote Connector (IN PDC) RELAY-RUN REMOTE (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay-Run Remote > Page 6339 Relay Box: Diagrams Relay-Run/Start Connector (IN PDC) RELAY-RUN/START (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) Relay Box: Application and ID Hev Power Distribution Center (PDC) HEV Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6342 Relay Box: Application and ID Integrated Power Module Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6343 Relay Box: Application and ID Junction Block Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6344 Relay Box: Application and ID Power Distribution Center Power Distribution Center W/O HEV Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) Description Relay Box: Description and Operation Power Distribution Center (PDC) - Description DESCRIPTION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) is located next to the Power Distribution Center (PDC) (3) in the engine compartment. The HEV PDC (4) works with the Front Control Module (FCM) (1), the Integrated Power Module (IPM) (2) and the PDC (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) Description > Page 6347 Relay Box: Description and Operation Power Distribution Center (PDC) - Operation OPERATION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) provides the extra power needed for the Hybrid Electric Vehicle (HEV). The HEV PDC provides power to: - Transmission Auxiliary Pump (TPCM) - Electric Vacuum Pump - Electric High Voltage Power Steering (EHPS) - Solid State Relay Electric Vacuum Pump The HEV PDC is serviced as part of the engine compartment body harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) Description > Page 6348 Relay Box: Description and Operation Junction Block - Description DESCRIPTION An electrical Junction Block (JB) (1) is concealed behind the left outboard end of the instrument panel cover. The JB combines the functions previously provided by a separate fuseblock module and relay center, serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as a fuse layout to help ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) Description > Page 6349 Relay Box: Description and Operation Junction Block - Operation OPERATION All of the circuits entering and leaving the JB do so through wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) Removal Relay Box: Service and Repair Power Distribution Center (PDC) - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Depress retaining tabs on the side on the PDC (1). 3. Disconnect electrical harness connectors (2) and remove PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) Removal > Page 6352 Relay Box: Service and Repair Power Distribution Center (PDC) - Installation INSTALLATION 1. Connect electrical harness connectors to Power Distribution Center (PDC). 2. Position PDC and engage into the retaining tabs. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) Removal > Page 6353 Relay Box: Service and Repair Junction Block - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left cowl trim cover. 3. Remove the mounting fasteners (3). 4. Disconnect the electrical harness connectors and remove Junction Block (1). 5. Transfer components as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) Removal > Page 6354 Relay Box: Service and Repair Junction Block - Installation INSTALLATION 1. Connect wire harness connectors to the Junction Block (JB) (1). 2. Position JB and install mounting fasteners (3). 3. Install left cowl trim cover. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) Relay Box: Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6359 Relay Box: Locations Remote Run Relay Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6360 Relay Box: Locations Run/Start Relay Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6361 Relay Box: Locations Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6362 Relay Box: Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Remote Run Relay Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6363 Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Run/Start Relay Run Remote Relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6364 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Junction Block Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay-Run Remote Relay Box: Diagrams Relay-Run Remote Connector (IN PDC) RELAY-RUN REMOTE (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay-Run Remote > Page 6367 Relay Box: Diagrams Relay-Run/Start Connector (IN PDC) RELAY-RUN/START (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) Relay Box: Application and ID Hev Power Distribution Center (PDC) HEV Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6370 Relay Box: Application and ID Integrated Power Module Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6371 Relay Box: Application and ID Junction Block Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6372 Relay Box: Application and ID Power Distribution Center Power Distribution Center W/O HEV Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description Relay Box: Description and Operation Power Distribution Center (PDC) - Description DESCRIPTION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) is located next to the Power Distribution Center (PDC) (3) in the engine compartment. The HEV PDC (4) works with the Front Control Module (FCM) (1), the Integrated Power Module (IPM) (2) and the PDC (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 6375 Relay Box: Description and Operation Power Distribution Center (PDC) - Operation OPERATION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) provides the extra power needed for the Hybrid Electric Vehicle (HEV). The HEV PDC provides power to: - Transmission Auxiliary Pump (TPCM) - Electric Vacuum Pump - Electric High Voltage Power Steering (EHPS) - Solid State Relay Electric Vacuum Pump The HEV PDC is serviced as part of the engine compartment body harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 6376 Relay Box: Description and Operation Junction Block - Description DESCRIPTION An electrical Junction Block (JB) (1) is concealed behind the left outboard end of the instrument panel cover. The JB combines the functions previously provided by a separate fuseblock module and relay center, serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as a fuse layout to help ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 6377 Relay Box: Description and Operation Junction Block - Operation OPERATION All of the circuits entering and leaving the JB do so through wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal Relay Box: Service and Repair Power Distribution Center (PDC) - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Depress retaining tabs on the side on the PDC (1). 3. Disconnect electrical harness connectors (2) and remove PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 6380 Relay Box: Service and Repair Power Distribution Center (PDC) - Installation INSTALLATION 1. Connect electrical harness connectors to Power Distribution Center (PDC). 2. Position PDC and engage into the retaining tabs. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 6381 Relay Box: Service and Repair Junction Block - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left cowl trim cover. 3. Remove the mounting fasteners (3). 4. Disconnect the electrical harness connectors and remove Junction Block (1). 5. Transfer components as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 6382 Relay Box: Service and Repair Junction Block - Installation INSTALLATION 1. Connect wire harness connectors to the Junction Block (JB) (1). 2. Position JB and install mounting fasteners (3). 3. Install left cowl trim cover. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Auxiliary Power Outlet Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Auxiliary Power Outlet Switch > Component Information > Locations > Page 6387 Auxiliary Power Outlet Switch: Diagrams Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-INVERTER - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Console Power Outlet Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Console Power Outlet > Page 6393 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations > Console Power Outlet > Page 6394 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6397 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6398 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6399 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6400 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6401 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6402 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6403 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6404 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6405 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6406 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6407 Auxiliary Power Outlet: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6408 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6409 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6410 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6411 Auxiliary Power Outlet: Connector Views AC Power Outlet (Center Console) 6 Way Connector - (CENTER CONSOLE) 6 WAY POWER OUTLET-AC - (CENTER CONSOLE) 6 WAY Console Power Outlet (Center Console) 3 Way Connector - (CENTER CONSOLE) 3 WAY POWER OUTLET-CONSOLE - (CENTER CONSOLE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6412 Instrument Panel Power Outlet (Instrument Panel) 3 Way Connector - (INSTRUMENT PANEL) 3 WAY POWER OUTLET-INSTRUMENT PANEL - (INSTRUMENT PANEL) 3 WAY Rear Power Outlet (Body) 3 Way Connector - (BODY) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6413 POWER OUTLET-REAR - (BODY) 3 WAY Rear Seat Power Outlet (Rear Seat) 3 Way Connector - (REAR SEAT) 3 WAY POWER OUTLET-REAR SEAT - (REAR SEAT) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6414 Auxiliary Power Outlet: Electrical Diagrams HORN/CIGAR LIGHTER/POWER OUTLET - Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6415 Horn/Cigar Lighter/Power Outlet 8W-41-01 Horn/Cigar Lighter/Power Outlet 8W-41-02 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6416 Horn/Cigar Lighter/Power Outlet 8W-41-03 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Power Outlet - Description Auxiliary Power Outlet: Description and Operation Power Outlet - Description DESCRIPTION INSTRUMENT PANEL MOUNTED An instrument panel mounted cigar lighter/power outlet receptacle is optional equipment on this model. On models equipped with the optional Smoker's Package, the cigar lighter knob and heating element are included. On models without the Smoker's Package, the cigar lighter receptacle is equipped with a snap fit plastic cap and is treated as an auxiliary power outlet. The cigar lighter receptacle is installed in the instrument panel accessory switch bezel, which is located near the bottom of the instrument panel center stack area, below the radio. The cigar lighter base is secured by a snap fit within the center lower bezel. This power outlet has a constant 12 volt battery feed. The cigar lighter receptacle is serviced with the accessory switch bezel and if defective, the entire switch bezel must be replaced. The plastic cap and the knob and heating element unit are available for service replacement. These components cannot be repaired and, if faulty or damaged, they must be replaced. FRONT CONSOLE AND REAR CARGO MOUNTED A front console mounted power outlet is standard equipment and a rear cargo area power outlet is optional equipment on this model. The front console mounted power outlet is mounted near the front of the console just in front of the cup holders. This outlet can be used as a cigar lighter or power outlet, but only has 12 volt battery voltage when the ignition is in the ON or ACC positions. The rear power outlet is installed in the right rear quarter trim panel, near the spare tire jack. The power outlet base and mount are secured by a snap fit within the quarter trim panel. A plastic protective cap snaps into the power outlet base when the power outlet is not being used, and hangs from the power outlet base mount by an integral bail strap while the power outlet is in use. While the power outlet is very similar to a cigar lighter base unit, it does not include the two small spring-clip retainers inside the bottom of the receptacle shell that are used to secure the cigar lighter heating element to the insulated contact. It has 12 volt battery voltage when the ignition is in the ON or ACC positions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Description and Operation > Power Outlet - Description > Page 6419 Auxiliary Power Outlet: Description and Operation Power Outlet - Operation OPERATION CIGAR LIGHTER/POWER OUTLET The cigar lighter consists of two major components: a knob and heating element unit, and the cigar lighter base or receptacle shell. The receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The cigar lighter knob and heating element are encased within a spring-loaded housing, which also features a sliding protective heat shield. When the knob and heating element are inserted in the receptacle shell, the heating element resistor coil is grounded through its housing to the receptacle shell. If the cigar lighter knob is pushed inward, the heat shield slides up toward the knob exposing the heating element, and the heating element extends from the housing toward the insulated contact in the bottom of the receptacle shell. Two small spring-clip retainers are located on either side of the insulated contact inside the bottom of the receptacle shell. These clips engage and hold the heating element against the insulated contact long enough for the resistor coil to heat up. When the heating element is engaged with the contact, battery current can flow through the resistor coil to ground, causing the resistor coil to heat. When the resistor coil becomes sufficiently heated, excess heat radiates from the heating element causing the spring-clips to expand. Once the spring-clips expand far enough to release the heating element, the spring-loaded housing forces the knob and heating element to pop back outward to their relaxed position. When the cigar lighter knob and element are pulled out of the receptacle shell, the protective heat shield slides downward on the housing so that the heating element is recessed and shielded around its circumference for safety. POWER OUTLET The power outlet base or receptacle shell is connected to ground, and an insulated contact in the bottom of the shell is connected to battery current. The power outlet receives battery voltage from a fuse in the Totally Integrated Power Module (TIPM) through a fuse in the fuse block when the ignition is in the ON or ACC positions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > AC Power Outlet - Removal Auxiliary Power Outlet: Service and Repair AC Power Outlet - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the center console. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Rear Center Console - Removal. 3. Disconnect electrical connector. 4. Remove AC power outlet. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > AC Power Outlet - Removal > Page 6422 Auxiliary Power Outlet: Service and Repair AC Power Outlet - Installation INSTALLATION 1. Connect the electrical connector. 2. Install the AC power outlet. 3. Install the center console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Installation. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > AC Power Outlet - Removal > Page 6423 Auxiliary Power Outlet: Service and Repair Power Outlet - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Look inside and note position of the retaining bosses (1). 3. Using special tool 9857 Power Outlet Remover. Insert the tool forcing the bosses out of base. 4. Pull out the base through mounting ring by gently rocking the tool (3). 5. Disconnect the base wires. 6. Set base aside and remove base mount ring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Service and Repair > AC Power Outlet - Removal > Page 6424 Auxiliary Power Outlet: Service and Repair Power Outlet - Installation INSTALLATION 1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and the mount ring with the index tab at 9 o'clock to the key in the instrument panel. Install the ring. 2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring at the same location. 3. Push base into the bezel till it locks. 4. Install cigar lighter cap. 5. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet Switch > Component Information > Locations > Page 6428 Auxiliary Power Outlet Switch: Diagrams Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-INVERTER - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations > Page 6432 Circuit Breaker: Diagrams Connector - 2 WAY CIRCUIT BREAKER - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel Fuse: Locations Fuse Panel FUSE PANELS WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions CAUTION: When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating. The use of a fuse with a rating other than indicated may result in a dangerous electrical system overload. If a properly rated fuse continues to blow, it suggests a problem in the circuit that must be corrected. NOTE: If leaving the vehicle dormant for longer than 21 days you may want to take steps to protect the battery. To do this disconnect the battery or disconnect the two Ignition Off Draw (IOD) fuses located in the auxiliary Power Distribution Center (PDC) in the engine compartment. The IOD cavities include a snap in retainer that allows the fuses to be disconnected without removing them from the fuse block. To reconnect the IOD fuses press them back into the cavity. Underhood Fuses Integrated Power Module (IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6437 IPM MODULE An Integrated Power Module (IPM) is located in the left side of the engine compartment. This center contains cartridge fuses, mini fuses and relays. A description of each fuse and component may be stamped on the inside cover, otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart. Integrated Power Module (IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6438 HEV Power Distribution Center (PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6439 The vehicle is equipped with an electrical Power Distribution Center (PDC) located in the left side of the engine compartment. This center contains cartridge fuses, mini fuses and relays. A description of each fuse and component may be stamped on the inside cover, otherwise the cavity number of each fuse is stamped on the inside cover that corresponds to the following chart. These fuses and relays can be obtained from your authorized dealer. HEV Power Distribution Center (PDC) - RELAYS HEV Power Distribution Center (PDC) - FUSES Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6440 HEV Power Distribution Center 2 (PDC2) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6441 HEV Power Distribution Center 2 (PDC2) Non-HEV Power Distribution Center (PDC) RELAYS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6442 FUSES Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6443 Interior Fuses Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6444 Junction Block Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6445 Fuse Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6446 The fuse block contains blade-type mini-fuses, relays, and circuit breakers for high-current circuits. It is located in the left kick panel. It is accessible through a snap-in cover. Fuse Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6447 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6448 Fuse: Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6449 Fuse: Locations Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6450 Fuse: Locations Junction Block Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Fuse Panel > Page 6451 Fuse: Locations Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Hev Power Distribution Center (PDC) Fuse: Application and ID Hev Power Distribution Center (PDC) HEV Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6454 Fuse: Application and ID Integrated Power Module Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6455 Fuse: Application and ID Junction Block Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6456 Fuse: Application and ID Power Distribution Center Power Distribution Center W/O HEV Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Description and Operation > IOD Fuse - Description Fuse: Description and Operation IOD Fuse - Description DESCRIPTION All vehicles are equipped with an Ignition-Off Draw (IOD) fuse that is disconnected within the Integrated Power Module when the vehicle is shipped from the factory. Dealer personnel are to reconnect the IOD fuse in the Integrated Power Module as part of the preparation procedures performed just prior to new vehicle delivery. The following circuits are protected by the IOD fuse: - Cluster (CCN) - Diagnostic Connector - Map Lamps - Glove Box Lamp - Courtesy Lamps - Radio - Underhood Lamp Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Description and Operation > IOD Fuse - Description > Page 6459 Fuse: Description and Operation IOD Fuse - Operation OPERATION The term ignition-off draw identifies a normal condition where power is being drained from the battery with the ignition switch in the Off position. The IOD fuse feeds the memory and sleep mode functions for some of the electronic modules in the vehicle as well as various other accessories that require battery current when the ignition switch is in the Off position. The only reason the IOD fuse is disconnected is to reduce the normal IOD of the vehicle electrical system during new vehicle transportation and pre-delivery storage to reduce battery depletion, while still allowing vehicle operation so that the vehicle can be loaded, unloaded and moved as needed. The IOD fuse is disconnected from Integrated Power Module when the vehicle is shipped from the assembly plant. Dealer personnel must reconnect the IOD fuse when the vehicle is being prepared for delivery in order to restore full electrical system operation. Once the vehicle is prepared for delivery, the IOD function of this fuse becomes transparent and the fuse that has been assigned the IOD designation becomes another Fused B(+) circuit fuse. The IOD fuse can be used by the vehicle owner as a convenient means of reducing battery depletion when a vehicle is to be stored for periods not to exceed about thirty days. However, it must be remembered that disconnecting the IOD fuse will not eliminate IOD, but only reduce this normal condition. If a vehicle will be stored for more than about thirty days, the battery negative cable should be disconnected to eliminate normal IOD; and, the battery should be tested and recharged at regular intervals during the vehicle storage period to prevent the battery from becoming discharged or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations Fuse Block: Component Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Junction Block Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 6464 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 6465 Fuse Block: Connector Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 6466 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 6467 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Component Locations > Page 6468 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6471 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6472 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6473 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6474 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6475 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6476 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6477 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6478 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6479 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6480 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6481 Fuse Block: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6482 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6483 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6484 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6485 Fuse Block: Connector Views Junction Block C1 (Headlamp And Dash) Connector C1 - (HEADLAMP AND DASH) JUNCTION BLOCK - (HEADLAMP AND DASH) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6486 Junction Block C2 (Instrument Panel Side) Connector C2 - (INSTRUMENT PANEL SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6487 JUNCTION BLOCK - (INSTRUMENT PANEL SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6488 Junction Block C3 (Body Side) Connector C3 - (BODY SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6489 JUNCTION BLOCK - (BODY SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6490 Junction Block C4 (Instrument Panel Side) Connector C4 - (INSTRUMENT PANEL SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6491 JUNCTION BLOCK - (INSTRUMENT PANEL SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6492 Junction Block C5 (Headlamp And Dash) Connector C5 - (HEADLAMP AND DASH) JUNCTION BLOCK - (HEADLAMP AND DASH) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 6493 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Hev Power Distribution Center (PDC) Fuse Block: Application and ID Hev Power Distribution Center (PDC) HEV Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6496 Fuse Block: Application and ID Integrated Power Module Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6497 Fuse Block: Application and ID Junction Block Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6498 Fuse Block: Application and ID Power Distribution Center Power Distribution Center W/O HEV Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Power Distribution Center (PDC) - Description Fuse Block: Description and Operation Power Distribution Center (PDC) - Description DESCRIPTION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) is located next to the Power Distribution Center (PDC) (3) in the engine compartment. The HEV PDC (4) works with the Front Control Module (FCM) (1), the Integrated Power Module (IPM) (2) and the PDC (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 6501 Fuse Block: Description and Operation Power Distribution Center (PDC) - Operation OPERATION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) provides the extra power needed for the Hybrid Electric Vehicle (HEV). The HEV PDC provides power to: - Transmission Auxiliary Pump (TPCM) - Electric Vacuum Pump - Electric High Voltage Power Steering (EHPS) - Solid State Relay Electric Vacuum Pump The HEV PDC is serviced as part of the engine compartment body harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 6502 Fuse Block: Description and Operation Junction Block - Description DESCRIPTION An electrical Junction Block (JB) (1) is concealed behind the left outboard end of the instrument panel cover. The JB combines the functions previously provided by a separate fuseblock module and relay center, serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as a fuse layout to help ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 6503 Fuse Block: Description and Operation Junction Block - Operation OPERATION All of the circuits entering and leaving the JB do so through wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal Fuse Block: Service and Repair Power Distribution Center (PDC) - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Depress retaining tabs on the side on the PDC (1). 3. Disconnect electrical harness connectors (2) and remove PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 6506 Fuse Block: Service and Repair Power Distribution Center (PDC) - Installation INSTALLATION 1. Connect electrical harness connectors to Power Distribution Center (PDC). 2. Position PDC and engage into the retaining tabs. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 6507 Fuse Block: Service and Repair Junction Block - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left cowl trim cover. 3. Remove the mounting fasteners (3). 4. Disconnect the electrical harness connectors and remove Junction Block (1). 5. Transfer components as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 6508 Fuse Block: Service and Repair Junction Block - Installation INSTALLATION 1. Connect wire harness connectors to the Junction Block (JB) (1). 2. Position JB and install mounting fasteners (3). 3. Install left cowl trim cover). 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-014-09 > Sep > 09 > EVIC Module Intermittent Or No Operation Power Distribution Module: Customer Interest EVIC Module - Intermittent Or No Operation NUMBER: 08-014-09 GROUP: Electrical DATE: September 3, 2009 SUBJECT: EVIC Module Intermittent or No Operation OVERVIEW: This bulletin involves inspecting the Satellite Antenna for looseness when making EVIC module repairs. MODELS: 2009 (HB) Durango (Includes Hybrid) 2009 (HG) Aspen (Includes Hybrid) SYMPTOM/CONDITION: The EVIC may intermittently operate or stop functioning. DISCUSSION: Before replacing the EVIC module, inspect the Satellite Antenna for looseness or for signs of water intrusion from around the antenna base. If looseness is found tighten the antenna before replacing the EVIC module. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-014-09 > Sep > 09 > EVIC Module - Intermittent Or No Operation Power Distribution Module: All Technical Service Bulletins EVIC Module - Intermittent Or No Operation NUMBER: 08-014-09 GROUP: Electrical DATE: September 3, 2009 SUBJECT: EVIC Module Intermittent or No Operation OVERVIEW: This bulletin involves inspecting the Satellite Antenna for looseness when making EVIC module repairs. MODELS: 2009 (HB) Durango (Includes Hybrid) 2009 (HG) Aspen (Includes Hybrid) SYMPTOM/CONDITION: The EVIC may intermittently operate or stop functioning. DISCUSSION: Before replacing the EVIC module, inspect the Satellite Antenna for looseness or for signs of water intrusion from around the antenna base. If looseness is found tighten the antenna before replacing the EVIC module. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center > Page 6527 Power Distribution Module: Locations Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center > Page 6528 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center > Page 6529 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way Power Distribution Module: Diagrams 110v Inverter Module (Right Seat) 9 Way Connector - (RIGHT SEAT) 9 WAY MODULE-110V INVERTER - (RIGHT SEAT) 9 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6532 Power Distribution Module: Diagrams Integrated Power Module C1 (Headlamp And Dash) 40 Way Connector C1 - (HEADLAMP AND DASH) 40 WAY MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6533 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6534 Power Distribution Module: Diagrams Integrated Power Module C2 (Headlamp And Dash) 40 Way Connector C2 - (HEADLAMP AND DASH) 40 WAY MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6535 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6536 Power Distribution Module: Diagrams Integrated Power Module C3 (Battery) 1 Way Connector C3 - (BATTERY) 1 WAY MODULE-INTEGRATED POWER - (BATTERY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6537 Power Distribution Module: Diagrams 110v Inverter Module (Right Seat) 9 Way Connector - (RIGHT SEAT) 9 WAY MODULE-110V INVERTER - (RIGHT SEAT) 9 WAY Integrated Power Module C1 (Headlamp And Dash) 40 Way Connector C1 - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6538 MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6539 Integrated Power Module C2 (Headlamp And Dash) 40 Way Connector C2 - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6540 MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6541 Integrated Power Module C3 (Battery) 1 Way Connector C3 - (BATTERY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6542 MODULE-INTEGRATED POWER - (BATTERY) 1 WAY Power Distribution Center (Battery) 1 Way Connector (BATTERY) - 1 WAY POWER DISTRIBUTION CENTER (BATTERY) - 1 WAY Power Distribution Center C1 (Hard Wired) 20 Way Connector C1 - (HARD WIRED) 20 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6543 POWER DISTRIBUTION CENTER - (HARD WIRED) 20 WAY Power Distribution Center C2 (Hard Wired) 14 Way Connector C2 - (HARD WIRED) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6544 POWER DISTRIBUTION CENTER - (HARD WIRED) 14 WAY Power Distribution Center C3 (Hard Wired) 41 Way Connector C3 - (HARD WIRED) 41 WAY POWER DISTRIBUTION CENTER - (HARD WIRED) 41 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6545 Power Distribution Center C4 (Hard Wired) 15 Way Connector C4 - (HARD WIRED) 15 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6546 POWER DISTRIBUTION CENTER - (HARD WIRED) 15 WAY Power Distribution Center C5 (Hard Wired) 15 Way Connector C5 - (HARD WIRED) 15 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6547 POWER DISTRIBUTION CENTER - (HARD WIRED) 15 WAY Power Distribution Center C6 (HEV) (Hard Wired) 11 Way Connector C6 (HEV) - (HARD WIRED) 11 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6548 POWER DISTRIBUTION CENTER (HEV) - (HARD WIRED) 11 WAY Power Distribution Center C7 (HEV) (Hard Wired) 22 Way Connector C7 (HEV) - (HARD WIRED) 22 WAY POWER DISTRIBUTION CENTER (HEV) - (HARD WIRED) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6549 HEV Power Distribution Center (HEV) (In PDC) Connector (HEV) - (IN PDC) FUSE 2 (HEV) - (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module (IPM) - Description Power Distribution Module: Description and Operation Integrated Power Module (IPM) - Description DESCRIPTION The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The IPM is located in the engine compartment, next to the battery. The power distribution center mates directly with the (FCM) to form the IPM. The (PDC) is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module (IPM) - Description > Page 6552 Power Distribution Module: Description and Operation Integrated Power Module (IPM) - Operation OPERATION All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal Power Distribution Module: Service and Repair Integrated Power Module (IPM) - Removal REMOVAL 1. Disconnect the negative and positive battery cables. 2. Unsnap cover and remove the B+ terminal nut from the integrated power module (IPM). Remove the B+ cable. 3. Remove the IPM from the retaining bracket (1). 4. Disconnect the connectors from the (IPM). 5. Remove the Front Control Module (FCM) (2) retaining screws. 6. Disconnect the front control module by pulling it straight off the integrated power module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal > Page 6555 Power Distribution Module: Service and Repair Integrated Power Module (IPM) - Installation INSTALLATION 1. Install the Front Control Module (FCM) (2) to the Integrated Power Module (IPM). 2. Connect the electrical connectors to the IPM (1). 3. Install the IPM to the retaining bracket. 4. Install the B+ cable and nut on the IPM B+ terminal. Snap the cover in place. 5. Connect the negative and positive battery cables. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal > Page 6556 Power Distribution Module: Service and Repair Power Inverter Module - Removal REMOVAL 1. Position the passenger front seat all the way back toward the rear of the vehicle. 2. Disconnect the power inverter electrical connector (1). 3. Remove the two mounting screws (2). 4. Position the front passenger seat all the way forward to gain access to the rear of the power inverter (2). 5. Remove the two rear mounting screws (1). 6. Remove the power inverter (2) by sliding it toward the driver seat. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal > Page 6557 Power Distribution Module: Service and Repair Power Inverter Module - Installation INSTALLATION 1. Install the power inverter (2) by sliding it toward the passenger door. 2. Install the two rear mounting screws (1). 3. Position the passenger front seat all the way back toward the rear of the vehicle. 4. Install the two front mounting screws (2). 5. Connect the power inverter electrical connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > Customer Interest for Power Distribution Module: > 08-014-09 > Sep > 09 > EVIC Module - Intermittent Or No Operation Power Distribution Module: Customer Interest EVIC Module - Intermittent Or No Operation NUMBER: 08-014-09 GROUP: Electrical DATE: September 3, 2009 SUBJECT: EVIC Module Intermittent or No Operation OVERVIEW: This bulletin involves inspecting the Satellite Antenna for looseness when making EVIC module repairs. MODELS: 2009 (HB) Durango (Includes Hybrid) 2009 (HG) Aspen (Includes Hybrid) SYMPTOM/CONDITION: The EVIC may intermittently operate or stop functioning. DISCUSSION: Before replacing the EVIC module, inspect the Satellite Antenna for looseness or for signs of water intrusion from around the antenna base. If looseness is found tighten the antenna before replacing the EVIC module. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Distribution Module: > 08-014-09 > Sep > 09 > EVIC Module - Intermittent Or No Operation Power Distribution Module: All Technical Service Bulletins EVIC Module - Intermittent Or No Operation NUMBER: 08-014-09 GROUP: Electrical DATE: September 3, 2009 SUBJECT: EVIC Module Intermittent or No Operation OVERVIEW: This bulletin involves inspecting the Satellite Antenna for looseness when making EVIC module repairs. MODELS: 2009 (HB) Durango (Includes Hybrid) 2009 (HG) Aspen (Includes Hybrid) SYMPTOM/CONDITION: The EVIC may intermittently operate or stop functioning. DISCUSSION: Before replacing the EVIC module, inspect the Satellite Antenna for looseness or for signs of water intrusion from around the antenna base. If looseness is found tighten the antenna before replacing the EVIC module. POLICY: Information Only. Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center > Page 6574 Power Distribution Module: Locations Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center > Page 6575 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Locations > Power Distribution Center > Page 6576 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way Power Distribution Module: Diagrams 110v Inverter Module (Right Seat) 9 Way Connector - (RIGHT SEAT) 9 WAY MODULE-110V INVERTER - (RIGHT SEAT) 9 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6579 Power Distribution Module: Diagrams Integrated Power Module C1 (Headlamp And Dash) 40 Way Connector C1 - (HEADLAMP AND DASH) 40 WAY MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6580 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6581 Power Distribution Module: Diagrams Integrated Power Module C2 (Headlamp And Dash) 40 Way Connector C2 - (HEADLAMP AND DASH) 40 WAY MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6582 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6583 Power Distribution Module: Diagrams Integrated Power Module C3 (Battery) 1 Way Connector C3 - (BATTERY) 1 WAY MODULE-INTEGRATED POWER - (BATTERY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6584 Power Distribution Module: Diagrams 110v Inverter Module (Right Seat) 9 Way Connector - (RIGHT SEAT) 9 WAY MODULE-110V INVERTER - (RIGHT SEAT) 9 WAY Integrated Power Module C1 (Headlamp And Dash) 40 Way Connector C1 - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6585 MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6586 Integrated Power Module C2 (Headlamp And Dash) 40 Way Connector C2 - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6587 MODULE-INTEGRATED POWER - (HEADLAMP AND DASH) 40 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6588 Integrated Power Module C3 (Battery) 1 Way Connector C3 - (BATTERY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6589 MODULE-INTEGRATED POWER - (BATTERY) 1 WAY Power Distribution Center (Battery) 1 Way Connector (BATTERY) - 1 WAY POWER DISTRIBUTION CENTER (BATTERY) - 1 WAY Power Distribution Center C1 (Hard Wired) 20 Way Connector C1 - (HARD WIRED) 20 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6590 POWER DISTRIBUTION CENTER - (HARD WIRED) 20 WAY Power Distribution Center C2 (Hard Wired) 14 Way Connector C2 - (HARD WIRED) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6591 POWER DISTRIBUTION CENTER - (HARD WIRED) 14 WAY Power Distribution Center C3 (Hard Wired) 41 Way Connector C3 - (HARD WIRED) 41 WAY POWER DISTRIBUTION CENTER - (HARD WIRED) 41 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6592 Power Distribution Center C4 (Hard Wired) 15 Way Connector C4 - (HARD WIRED) 15 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6593 POWER DISTRIBUTION CENTER - (HARD WIRED) 15 WAY Power Distribution Center C5 (Hard Wired) 15 Way Connector C5 - (HARD WIRED) 15 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6594 POWER DISTRIBUTION CENTER - (HARD WIRED) 15 WAY Power Distribution Center C6 (HEV) (Hard Wired) 11 Way Connector C6 (HEV) - (HARD WIRED) 11 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6595 POWER DISTRIBUTION CENTER (HEV) - (HARD WIRED) 11 WAY Power Distribution Center C7 (HEV) (Hard Wired) 22 Way Connector C7 (HEV) - (HARD WIRED) 22 WAY POWER DISTRIBUTION CENTER (HEV) - (HARD WIRED) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Diagrams > 110v Inverter Module (Right Seat) 9 Way > Page 6596 HEV Power Distribution Center (HEV) (In PDC) Connector (HEV) - (IN PDC) FUSE 2 (HEV) - (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module (IPM) Description Power Distribution Module: Description and Operation Integrated Power Module (IPM) - Description DESCRIPTION The Integrated Power Module (IPM) is a combination of the Power Distribution Center (PDC) (1) and the Front Control Module (FCM) (2). The IPM is located in the engine compartment, next to the battery. The power distribution center mates directly with the (FCM) to form the IPM. The (PDC) is a printed circuit board based module that contains fuses and relays, while the FCM contains the electronics controlling the IPM and other functions. The IPM connects directly to the battery positive via a stud located on top of the unit. The ground connection is via electrical connectors. The IPM provides the primary means of voltage distribution and protection for the entire vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Description and Operation > Integrated Power Module (IPM) Description > Page 6599 Power Distribution Module: Description and Operation Integrated Power Module (IPM) - Operation OPERATION All of the current from the battery and the generator output enters the integrated power module via a stud on the top of the module. Internal connections of all of the power distribution center circuits is accomplished by a combination of bus bars and a printed circuit board. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal Power Distribution Module: Service and Repair Integrated Power Module (IPM) - Removal REMOVAL 1. Disconnect the negative and positive battery cables. 2. Unsnap cover and remove the B+ terminal nut from the integrated power module (IPM). Remove the B+ cable. 3. Remove the IPM from the retaining bracket (1). 4. Disconnect the connectors from the (IPM). 5. Remove the Front Control Module (FCM) (2) retaining screws. 6. Disconnect the front control module by pulling it straight off the integrated power module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal > Page 6602 Power Distribution Module: Service and Repair Integrated Power Module (IPM) - Installation INSTALLATION 1. Install the Front Control Module (FCM) (2) to the Integrated Power Module (IPM). 2. Connect the electrical connectors to the IPM (1). 3. Install the IPM to the retaining bracket. 4. Install the B+ cable and nut on the IPM B+ terminal. Snap the cover in place. 5. Connect the negative and positive battery cables. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal > Page 6603 Power Distribution Module: Service and Repair Power Inverter Module - Removal REMOVAL 1. Position the passenger front seat all the way back toward the rear of the vehicle. 2. Disconnect the power inverter electrical connector (1). 3. Remove the two mounting screws (2). 4. Position the front passenger seat all the way forward to gain access to the rear of the power inverter (2). 5. Remove the two rear mounting screws (1). 6. Remove the power inverter (2) by sliding it toward the driver seat. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Distribution Module > Component Information > Service and Repair > Integrated Power Module (IPM) - Removal > Page 6604 Power Distribution Module: Service and Repair Power Inverter Module - Installation INSTALLATION 1. Install the power inverter (2) by sliding it toward the passenger door. 2. Install the two rear mounting screws (1). 3. Position the passenger front seat all the way back toward the rear of the vehicle. 4. Install the two front mounting screws (2). 5. Connect the power inverter electrical connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) Relay Box: Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6609 Relay Box: Locations Remote Run Relay Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6610 Relay Box: Locations Run/Start Relay Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6611 Relay Box: Locations Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6612 Relay Box: Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Remote Run Relay Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6613 Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Run/Start Relay Run Remote Relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6614 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Junction Block Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay-Run Remote Relay Box: Diagrams Relay-Run Remote Connector (IN PDC) RELAY-RUN REMOTE (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay-Run Remote > Page 6617 Relay Box: Diagrams Relay-Run/Start Connector (IN PDC) RELAY-RUN/START (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) Relay Box: Application and ID Hev Power Distribution Center (PDC) HEV Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6620 Relay Box: Application and ID Integrated Power Module Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6621 Relay Box: Application and ID Junction Block Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6622 Relay Box: Application and ID Power Distribution Center Power Distribution Center W/O HEV Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description Relay Box: Description and Operation Power Distribution Center (PDC) - Description DESCRIPTION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) is located next to the Power Distribution Center (PDC) (3) in the engine compartment. The HEV PDC (4) works with the Front Control Module (FCM) (1), the Integrated Power Module (IPM) (2) and the PDC (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 6625 Relay Box: Description and Operation Power Distribution Center (PDC) - Operation OPERATION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) provides the extra power needed for the Hybrid Electric Vehicle (HEV). The HEV PDC provides power to: - Transmission Auxiliary Pump (TPCM) - Electric Vacuum Pump - Electric High Voltage Power Steering (EHPS) - Solid State Relay Electric Vacuum Pump The HEV PDC is serviced as part of the engine compartment body harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 6626 Relay Box: Description and Operation Junction Block - Description DESCRIPTION An electrical Junction Block (JB) (1) is concealed behind the left outboard end of the instrument panel cover. The JB combines the functions previously provided by a separate fuseblock module and relay center, serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as a fuse layout to help ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 6627 Relay Box: Description and Operation Junction Block - Operation OPERATION All of the circuits entering and leaving the JB do so through wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal Relay Box: Service and Repair Power Distribution Center (PDC) - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Depress retaining tabs on the side on the PDC (1). 3. Disconnect electrical harness connectors (2) and remove PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 6630 Relay Box: Service and Repair Power Distribution Center (PDC) - Installation INSTALLATION 1. Connect electrical harness connectors to Power Distribution Center (PDC). 2. Position PDC and engage into the retaining tabs. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 6631 Relay Box: Service and Repair Junction Block - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left cowl trim cover. 3. Remove the mounting fasteners (3). 4. Disconnect the electrical harness connectors and remove Junction Block (1). 5. Transfer components as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 6632 Relay Box: Service and Repair Junction Block - Installation INSTALLATION 1. Connect wire harness connectors to the Junction Block (JB) (1). 2. Position JB and install mounting fasteners (3). 3. Install left cowl trim cover. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) Relay Box: Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6637 Relay Box: Locations Remote Run Relay Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6638 Relay Box: Locations Run/Start Relay Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6639 Relay Box: Locations Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6640 Relay Box: Locations Hev Power Distribution Center (PDC) HEV Power Distribution Center (PDC) HEV Power Distribution Center is located next to the Power Distribution Center (PDC), in the left front corner of the engine compartment. Remote Run Relay Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6641 Run Remote Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Run/Start Relay Run Remote Relay is located in the Power Distribution Center (PDC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Hev Power Distribution Center (PDC) > Page 6642 Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Integrated Power Module Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Junction Block Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Power Distribution Center Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay-Run Remote Relay Box: Diagrams Relay-Run Remote Connector (IN PDC) RELAY-RUN REMOTE (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay-Run Remote > Page 6645 Relay Box: Diagrams Relay-Run/Start Connector (IN PDC) RELAY-RUN/START (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) Relay Box: Application and ID Hev Power Distribution Center (PDC) HEV Power Distribution Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6648 Relay Box: Application and ID Integrated Power Module Integrated Power Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6649 Relay Box: Application and ID Junction Block Junction Block Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Hev Power Distribution Center (PDC) > Page 6650 Relay Box: Application and ID Power Distribution Center Power Distribution Center W/O HEV Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description Relay Box: Description and Operation Power Distribution Center (PDC) - Description DESCRIPTION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) is located next to the Power Distribution Center (PDC) (3) in the engine compartment. The HEV PDC (4) works with the Front Control Module (FCM) (1), the Integrated Power Module (IPM) (2) and the PDC (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 6653 Relay Box: Description and Operation Power Distribution Center (PDC) - Operation OPERATION The Hybrid Electric Vehicle Power Distribution Center (HEV PDC) provides the extra power needed for the Hybrid Electric Vehicle (HEV). The HEV PDC provides power to: - Transmission Auxiliary Pump (TPCM) - Electric Vacuum Pump - Electric High Voltage Power Steering (EHPS) - Solid State Relay Electric Vacuum Pump The HEV PDC is serviced as part of the engine compartment body harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 6654 Relay Box: Description and Operation Junction Block - Description DESCRIPTION An electrical Junction Block (JB) (1) is concealed behind the left outboard end of the instrument panel cover. The JB combines the functions previously provided by a separate fuseblock module and relay center, serves to simplify and centralize numerous electrical components, and to distribute electrical current to many of the accessory systems in the vehicle. It also eliminates the need for numerous splice connections and serves in place of a bulkhead connector between many of the engine compartment, instrument panel, and body wire harnesses. The molded plastic JB housing has integral mounting brackets that are secured with two screws to the left instrument panel end bracket. The left end of the instrument panel cover has a snap-fit fuse access panel that can be removed for service of the JB. A fuse puller and spare fuse holders are located on the back of the fuse access cover, as well as a fuse layout to help ensure proper fuse identification. The JB unit cannot be repaired and is only serviced as an assembly. If any internal circuit or the JB housing is faulty or damaged, the entire JB unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Description and Operation > Power Distribution Center (PDC) - Description > Page 6655 Relay Box: Description and Operation Junction Block - Operation OPERATION All of the circuits entering and leaving the JB do so through wire harness connectors, which are connected to the JB through integral connector receptacles molded into the JB housing. Internal connection of all of the JB circuits is accomplished by an intricate combination of hard wiring and bus bars. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal Relay Box: Service and Repair Power Distribution Center (PDC) - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Depress retaining tabs on the side on the PDC (1). 3. Disconnect electrical harness connectors (2) and remove PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 6658 Relay Box: Service and Repair Power Distribution Center (PDC) - Installation INSTALLATION 1. Connect electrical harness connectors to Power Distribution Center (PDC). 2. Position PDC and engage into the retaining tabs. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 6659 Relay Box: Service and Repair Junction Block - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left cowl trim cover. 3. Remove the mounting fasteners (3). 4. Disconnect the electrical harness connectors and remove Junction Block (1). 5. Transfer components as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Power Distribution Center (PDC) - Removal > Page 6660 Relay Box: Service and Repair Junction Block - Installation INSTALLATION 1. Connect wire harness connectors to the Junction Block (JB) (1). 2. Position JB and install mounting fasteners (3). 3. Install left cowl trim cover. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Auxiliary Power Outlet Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Power and Ground Distribution > Sensors and Switches - Power and Ground Distribution > Auxiliary Power Outlet Switch > Component Information > Locations > Page 6665 Auxiliary Power Outlet Switch: Diagrams Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-INVERTER - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment Alignment: Specifications Wheel Alignment WHEEL ALIGNMENT NOTE: All alignment specifications are in degrees. 4X2 4x4 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment > Page 6671 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Wheel Alignment > Page 6672 Alignment: Specifications Curb Height Measurement FRONT CURB HEIGHT MEASUREMENT Difference between spindle and control arm bolt to ground distances should be 81 mm +/- 3.2 mm (3.18 in +/- 0.12 in) REAR CURB HEIGHT MEASUREMENT The difference between the jounce bumper landing pad and the jounce bumper cup lip. The reading should be 148 mm +/-10 mm (5.8 in +/- 0.40 in) for 9.25" axle, 154 mm +/-10 mm (6.0 in +/0.40 in) for 8.25" axle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Description Alignment: Description and Operation Description DESCRIPTION NOTE: Suspension components with rubber/urethane bushings should be tightened with the vehicle at normal ride height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur. Wheel alignment involves the correct positioning of the wheels in relation to the vehicle. The positioning is accomplished through suspension and steering linkage adjustments. An alignment is considered essential for efficient steering, good directional stability and to minimize tire wear. The most important measurements of an alignment are caster, camber and toe. CAUTION: Never attempt to modify suspension or steering components by heating or bending. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Description > Page 6675 Alignment: Description and Operation Operation OPERATION - CASTER (1) is the forward or rearward tilt of the steering knuckle from vertical. Tilting the top of the knuckle forward provides less positive caster. Tilting the top of the knuckle rearward provides more positive caster. Positive caster promotes directional stability. This angle enables the front wheels to return to a straight ahead position after turns. - CAMBER (2) is the inward or outward tilt of the wheel relative to the center of the vehicle. Tilting the top of the wheel inward provides negative camber. Tilting the top of the wheel outward provides positive camber. Incorrect camber will cause wear on the inside or outside edge of the tire. - TOE (4) is the difference between the leading inside edges and trailing inside edges of the front tires. Wheel toe position out of specification cause's unstable steering, uneven tire wear and steering wheel off- center. The wheel toe position is the final front wheel alignment adjustment. - THRUST ANGLE (3) is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and excessive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation > Page 6676 Alignment: Testing and Inspection PRE-ALIGNMENT INSPECTION Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart below for additional information. NOTE: Vehicle should have a full tank of fuel prior to measuring and adjusting alignment. 1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. Inspect front wheels for excessive radial or lateral runout and balance. 4. Inspect ball studs, linkage pivot points and steering gear for looseness, roughness or binding. 5. Inspect suspension components for wear and noise. 6. Check suspension ride height. 7. Road test the vehicle. SUSPENSION AND STEERING SYSTEM DIAGNOSIS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Height Measurement Alignment: Service and Repair Height Measurement HEIGHT MEASUREMENT The vehicle suspension height MUST be measured and adjusted before performing wheel alignment procedure. Also when front suspension components have been replaced. This measure must be performed with the vehicle supporting it's own weight and taken on both sides of the vehicle. NOTE: Vehicle should have a full tank of fuel prior to measuring and adjusting alignment. FRONT CURB HEIGHT MEASUREMENT 1. Inspect tires and set to correct pressure. 2. Jounce the front of the vehicle. 3. With vehicle on level ground or hoist, make the following measurements: a. Front wheel spindle (center) (1) to ground vertical distance (3). b. Center of the front face of bolt on the rear leg of Lower control arm (2) to ground vertical distance (3). c. Difference between spindle and control arm bolt to ground distances should be 81 mm +/- 3.2 mm (3.18 in +/- 0.12 in)Note that the control arm bolt is lower than the spindle. 4. If adjustment is required, turn the torsion bar adjuster bolts- if lowering curb height, unscrew Torsion bar adjuster bolt beyond desired point so as to set height when screwing-in adjuster bolt. 5. After making any curb height adjustment, roll vehicle preferably jouncing it also, to relieve camber Effects and then re-measure Lower control arm bolt to ground height. 6. Repeat the previous steps until the curb height is within specifications. REAR CURB HEIGHT MEASUREMENT 1. Inspect tires and set to correct pressure. 2. Jounce the front of the vehicle. 3. With vehicle on level ground or hoist, make the following measurements: a. Distance from the landing pad of the jounce bumper on the axle side to the jounce bumper cup lip of the frame side. b. The difference between the jounce bumper landing pad and the jounce bumper cup lip. The reading should be 148 mm +/-10 mm (5.8 in +/0.40 in) for 9.25" axle, 154 mm +/-10 mm (6.0 in +/- 0.40 in) for 8.25" axle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Height Measurement > Page 6679 Alignment: Service and Repair Height Adjustment HEIGHT ADJUSTMENT The vehicle suspension height MUST be measured and adjusted before performing wheel alignment procedure See: . Also when front suspension components have been replaced. This measurement must be performed with the vehicle supporting it's own weight and taken on both sides of the vehicle. To adjust the vehicle height turn the torsion bar adjustment bolt CLOCKWISE to raise the vehicle and COUNTER CLOCKWISE to lower the vehicle. CAUTION: ALWAYS raise the vehicle to the correct suspension height, NEVER lower the vehicle to obtain the correct suspension height. If the vehicle suspension height is too high, lower the vehicle below the height specification. Then raise the vehicle to the correct suspension height specification. This will insure the vehicle maintains the proper suspension height. NOTE: If a height adjustment has been made, perform height measurement again on both sides of the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Height Measurement > Page 6680 Alignment: Service and Repair Camber, Caster and Toe Adjustment CAMBER, CASTER AND TOE ADJUSTMENT NOTE: Suspension height measurement must be performed before an alignment. Camber and caster angle adjustments involve changing the position of the lower control arm with the slots in the frame brackets to move the lower control arm inwards or outwards for proper adjustment. This can be achieved by using a long pry bar with a curved tip and inserting the pry bar into the lower control arm frame brackets and prying inwards or outwards. NOTE: Camber and caster adjustments must be made at the lower control arm. Do not use the upper control arm for Camber and Caster adjustments. NOTE: When the lower control arm pivot bolts are loosened the lower control arm will normally go outwards automatically with the weight of the vehicle. CASTER Moving the rear position of the lower control arm at the frame in or out, will change the caster angle significantly and camber angle only slightly. To maintain the camber angle while adjusting caster, move the rear of the lower control arm in or out. Then move the front of the lower control arm slightly in the opposite direction. CAMBER Move both the front and rear of the lower control arm together in or out. This will change the camber angle significantly and caster angle slightly. After adjustment is made tighten the lower control arm bolt AND nuts to 244 Nm (180 ft. lbs.). TOE ADJUSTMENT The wheel toe position adjustment is the final adjustment. 1. Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. 2. Loosen the tie rod jam nuts (3). NOTE: Each front wheel should be adjusted for one-half of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 3. Adjust the wheel toe position by turning the inner tie rod (4) as necessary. 4. Tighten the tie rod jam nut (3) to 130 Nm (96 ft. lbs.). 5. Verify the specifications. 6. Turn off engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 6687 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 6688 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way Tire Pressure Monitor Receiver / Transponder: Diagrams Left Front Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT FRONT - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way > Page 6691 Tire Pressure Monitor Receiver / Transponder: Diagrams Left Rear Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT REAR - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way > Page 6692 Tire Pressure Monitor Receiver / Transponder: Diagrams Right Front Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-RIGHT FRONT - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Description DESCRIPTION PREMIUM SYSTEM A transponder, also known as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of the vehicle to provide the WCM/SKREEM with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description > Page 6695 Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Operation OPERATION NUMBER: PREMIUM SYSTEM On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (Each WCM cycle ends when the vehicle has been shut off for a time period of approximately 15 minutes or longer). Once the WCM has performed this to the three locations that have transponders (left front, right front, and left rear wheel wells), it uses the process-of-elimination theory to know that the fourth sensor ID signal is coming from the left rear tire sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Removal Front FRONT TRANSPONDER 1. Raise and support the vehicle. 2. Remove the wheel well housing cover (2). 3. Remove the mounting nut (1) for the transponder (2). 4. Disconnect the electrical connector and remove the transponder (2) from the vehicle. Rear REAR TRANSPONDER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 6698 1. Raise and support the vehicle. 2. Remove the mounting nut (1) for the transponder (2). 3. Disconnect the electrical connector (3) and remove the transponder (2) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 6699 Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Installation Front FRONT TRANSPONDER 1. Install the transponder (2) to the vehicle and reconnect the electrical connector. 2. Install the mounting nuts (1) for the transponder (2) Tighten to 3 Nm (25 in. lbs.). 3. Install the wheel well housing cover (2). 4. Lower the vehicle. Rear REAR TRANSPONDER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 6700 1. Install the transponder (2) to the vehicle and reconnect the electrical connector (3) and secure the harness to the stud (4). 2. Install the mounting nut (1) for the transponder (2). Tighten to 3 Nm (25 in. lbs.). 3. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The TPMS has been optimized for the original equipment tires and wheels. TPMS pressures have been established for the tire size equipped on your vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, and/or style. After-market wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with a TPMS, as damage to the sensors may result. NOTE: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Any time a sensor is to be reinstalled in a wheel, a new seal, cap and valve core must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION NOTE: On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 or 433 MHz radio frequency. The 315 MHz sensors can be easily identified by a black sensor body, with (an oval insignia) (1). The 433 MHz sensors can be identified by a grey sensor body with an oval insignia. NOTE: If replacing the WCM, the spare tire must be dismounted from its wheel to access and note the spare tire pressure sensor ID. Then follow the programming steps outlined in the diagnostic scan tool for "Learn Spare Tire Sensor ID" under Miscellaneous Functions for the WCM wireless control module menu item as appropriate. In addition, the placard pressure thresholds must be updated in the new WCM. Go to "Update Pressure Thresholds" under Miscellaneous Functions for the WCM wireless control module and follow the procedure. On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a black sensor body, with (an oval insignia) (1) and a grey valve cap (2). The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by a gray sensor body (with an oval insignia) and a black valve cap (2). CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Domestic vehicles, use the 315 MHz TPM sensors with the BLACK sensor body. For Export vehicles, use the 433 MHz TPM sensors with the GREY sensor body. Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct color sensor is being used. A RKE-TPM Analyzer can be used to determine the sensor's frequency without having to dismount the tire. NOTE: If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel. (This could cause sealing and system performance issues). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 6708 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (4) - Valve Stem Cap (2) - Valve Stem Core - Valve Stem Nut (3) The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 6709 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit if using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor's operating mode and to diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following modes: - Sleep Mode - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. - Park Mode - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 PSI delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure 30 Block Mode - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to Park Mode using a TPM-RKE Analyzer, the sensor's operating mode will transition from Park Mode to 30 Block Mode once the vehicle is driven over 15mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 8 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to Drive Mode - Drive Mode - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time that the vehicle speed drops below 15mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h). If the vehicle has been stationary for more then 20 minutes, the TPM sensor will change to PARK MODE. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 m.p.h. (24 Km/h)" after a sensor has been replaced, The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The sensor IDs can also be programmed using the TPM-RKE Analyzer Tool. Scan each TPM sensor at each road wheel, and store each Sensor ID in the correct location. (LEFT FRONT, LEFT REAR, RIGHT FRONT, and RIGHT REAR) Connect the TPM-RKE Analyzer Tool to the Scan Tool. Then follow the programming steps outlined in the diagnostic Scan Tool for "Program Tire Pressure Sensor ID w/ TPM Tool" under "MISC" for the "WCM/WIRELESS CONTROL MODULE". Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6712 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6713 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 6 Nm (53 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6714 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the outer and inner tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. 8. Remove the support and lower the vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6715 b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Front Knuckle - Description Front Steering Knuckle: Description and Operation Front Knuckle - Description DESCRIPTION The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Description and Operation > Front Knuckle - Description > Page 6721 Front Steering Knuckle: Description and Operation Front Knuckle - Operation OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal Front Steering Knuckle: Service and Repair Front Steering Knuckle - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, rotor See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal , shield and ABS wheel speed sensor if equipped See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor - Removal/Front. 4. Remove the front half shaft nut 4X4 only. 5. Remove the tie rod end nut. Separate the tie rod (2) from the knuckle with puller 8677 (1). CAUTION: When installing puller 8677 to separate the ball joint, be careful not to damage the ball joint seal. 6. Remove the upper ball joint nut. Separate the ball joint (1) from the knuckle (3) with Remover 8677 (2). 7. Install an hydraulic jack to support the lower control arm. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6724 8. Remove the lower ball joint nut. Separate the ball joint from the knuckle (1) with Remover 8677 (2) and remove the knuckle. 9. Remove the hub/bearing bolts (1) from the knuckle. 10. Remove the hub/bearing (4) from the steering knuckle (1) See: Suspension/Wheel Bearing/Service and Repair/Front Hub and Bearing - Removal. 11. Remove the steering knuckle (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6725 Front Steering Knuckle: Service and Repair Front Steering Knuckle - Installation INSTALLATION CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. 1. Install the hub/bearing to the steering knuckle and tighten the bolts (1) to 163 Nm (120 ft. lbs.). 2. Install the knuckle (1) onto the upper and lower ball joints. 3. Install the upper ball joint nut. Tighten the nut to 75 Nm (55 ft. lbs.). 4. Install the lower ball joint nut (3). Tighten the nut to 95 Nm (70 ft. lbs.). 5. Remove the hydraulic jack from the lower suspension arm (2). 6. Install the tie rod end and tighten the nut to 75 Nm (55 ft. lbs.). 7. Install the front halfshaft (2) into the hub/bearing 4X4 only. 8. Install the the halfshaft nut and tighten to 251 Nm (185 ft. lbs.) 4X4 only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6726 9. Install the ABS wheel speed sensor if equipped See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor - Installation/Front and brake shield, rotor and caliper See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. 10. Install the wheel and tire assembly See: Wheels and Tires/Service and Repair/Removal and Replacement. 11. Remove the support and lower the vehicle. 12. Perform a wheel alignment See: Alignment/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair POWER STEERING SYSTEM BLEEDING - 5.7L (HEV) WARNING: The fluid level should be checked with engine off to prevent injury from moving components. CAUTION: MOPAR(R) Pentosan CHF 11S MOPAR(R) part # 05127381AA is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. CAUTION: If the air is not purged from the power steering system correctly, pump failure could result. NOTE: Be sure the vacuum tool used in the following procedure is clean and free of any fluids. 1. Check the fluid level. The level should indicate between MAX and MIN when the fluid is at normal ambient temperature. Adjust the fluid level as necessary. See: Service and Repair/Power Steering Fluid Level Checking 2. Tightly insert Power Steering Cap Adapter 9688A (4), into the mouth of the reservoir (3). CAUTION: Failure to use a vacuum pump reservoir (1) may allow power steering fluid to be sucked into the hand vacuum pump. 3. Attach Hand Vacuum Pump C-4207 (2) or equivalent, with reservoir (1) attached, to the Power Steering Cap Adapter (4). CAUTION: Do not run the vehicle while vacuum is applied to the power steering system. Damage to the power steering pump can occur. NOTE: When performing the following step make sure the vacuum level is maintained during the entire time period. 4. Using Hand Vacuum Pump (2), apply 68-85 kPa (20-25 in. Hg) of vacuum to the system for a minimum of three minutes. 5. Slowly release the vacuum and remove the special tools. 6. Adjust the fluid level as necessary. Refer to 1. 7. Repeat 1 through 6 until the fluid no longer drops when vacuum is applied. 8. Start the engine and cycle the steering wheel lock-to-lock three times. NOTE: Do not hold the steering wheel at the stops. 9. Stop the engine and check for leaks at all connections. 10. Check for any signs of air in the reservoir and check the fluid level. If air is present, repeat the procedure as necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information Power Steering Fluid: Technical Service Bulletins Maintenance - Fluid Flushing Information NUMBER: 26-001-09 GROUP: Miscellaneous DATE: September 24, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 26-003-07, DATED MARCH 30, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Fluid Flushing Requirements MODELS: 2005 - 2008 (CS) Pacifica 2006 - 2009 (D1) Ram Truck (3500 Pick Up) 2010 (D2) Ram Truck (3500 Pick Up) 2007 - 2010 (DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2005 - 2008 (DR) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2005 - 2009 (HB) Durango 2007 - 2009 (HG) Aspen 2009 - 2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2005 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan 2007 - 2010 (JS) Avenger/Sebring 2008 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2005 - 2007 (KJ) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2005 - 2006 (PL) Neon 2007 - 2010 (PM) Caliber 2005 - 2010 (PT) Chrysler PT Cruiser Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Maintenance - Fluid Flushing Information > Page 6735 2005 - 2007 (RG) Chrysler Voyager (International Markets) 2005 - 2007 (RS) Town & Country/Caravan/Voyager 2009 - 2010 (RT) Town & Country/Grand Caravan 2005 - 2006 (TJ) Wrangler 2005 - 2006 (VA) Sprinter 2007 - 2010 (VB) Sprinter 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander 2005 - 2010 (ZB) Viper 2005 - 2007 (ZH) Crossfire DISCUSSION: Chrysler Group vehicle fluid systems do NOT require regular flushing. These systems include: engine oil, transmission oil, axle lube, brake fluid, power steering fluid, and refrigerant. The only exception to this requirement are published in the vehicle maintenance schedules, e.g. engine coolant. Exceptions to this recommendation include only those instances where a failure has occurred and/or the system has become compromised, contaminated or overheated beyond the normal operating range. Chrysler Group does NOT recommend aftermarket chemicals to flush the engine, transmission, brake or steering systems. Chemicals contained in these products can damage the system elastomeric components, and contaminate the component fluid, leading to loss of system/component durability and service life. When necessary, only the original approved system fluid should be used to flush these components using teamPSE(R) approved equipment. If the engine coolant contains a considerable amount of sediment, clean and flush with Mopar Cooling System Flush, p/n 04856977, or equivalent. Follow with a thorough rinsing to remove all deposits and chemicals. Refill with a minimum of a 50% mixture of the specified coolant and distilled water. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6736 Power Steering Fluid: Specifications Power Steering Reservoir Belt Driven Pump ......................... Mopar Power Steering +4, or Mopar ATF +4 Automatic Transmission Fluid is required in the power steering system. Electric Power Steering (EPS) ................................................................................................................. Mopar hydraulic fluid, part number 05127381AA Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6737 Power Steering Fluid: Description and Operation POWER STEERING FLUID There are two types of power steering systems used on this vehicle. The conventional belt driven power steering pump system as well as an Electric Power Steering (EPS) pump system. The EPS pump is used on the 5.7L Hybrid Electric Vehicle (HEV) while the conventional system is used on all other vehicles. BELT DRIVEN PUMP (CONVENTIONAL) Mopar(R) ATF +4, Automatic Transmission Fluid is required in the power steering system. Substitute fluids can induce power steering system failure.Mopar(R) ATF +4, Automatic Transmission Fluid when new is red in color. The ATF is dyed red so it can be identified from other fluids used in the vehicle such as engine oil or antifreeze. The red color is not permanent and is not an indicator of fluid condition. As the vehicle is driven, the ATF will begin to look darker in color and may eventually become brown. This is normal. ATF+4 also has a unique odor that may change with age. Consequently, odor and color cannot be used to indicate the fluid condition or the need for a fluid change. EPS PUMP (5.7L HEV) The power steering system is filled at the factory with Pentosan CHF 11S. If necessary, use Mopar(R) hydraulic fluid, part number 05127381AA. Steering noise and reduced component life may result if an unapproved fluid is used. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 6738 Power Steering Fluid: Service and Repair POWER STEERING FLUID LEVEL CHECKING - 5.7L (HEV) WARNING: FLUID LEVEL SHOULD BE CHECKED WITH THE ENGINE OFF TO PREVENT PERSONAL INJURY FROM MOVING PARTS. CAUTION: MOPAR(R) Pentosan CHF 11S MOPAR(R) part # 05127381AA is to be used in the power steering system. No other power steering or automatic transmission fluid is to be used in the system. Damage may result to the power steering pump and system if any other fluid is used, and do not overfill. The power steering fluid level can be viewed on the dipstick attached to the filler cap. Before opening power steering system, wipe the reservoir filler cap free of dirt and debris. Remove the cap and check the fluid level on its dipstick. When the fluid is at normal ambient temperature, approximately 21° C to 27°C (70°F to 80°F), the fluid level should read between the minimum and maximum area of the dipstick. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal Power Steering Line/Hose: Service and Repair Power Steering Hose - Removal Pressure Hose PRESSURE HOSE 1. Siphon the fluid from the power steering pump reservoir (1). 2. Raise and support the vehicle. 3. Remove the left front wheel. 4. Remove the inner fender See: Body and Frame/Fender/Front Fender/Service and Repair/Front Fender - Removal 5. Remove the return hose (5) at the gear to gain access to the pressure hose (4). 6. Remove the pressure hose (4) at the gear. 7. Disconnect the pressure hose from the retainer at the crossmember. 8. Remove the pressure hose (4) at the pump pressure hose extension (6). 9. Remove the pressure hose (4) from the vehicle. Return Hose RETURN HOSE 1. Siphon the fluid from the power steering pump reservoir (1). 2. Raise and support the vehicle. 3. Remove the left front wheel. 4. Remove the inner wheel well See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation 5. Disconnect the return hose from the retainer at the crossmember. 6. Remove the return hose (5) at the gear. 7. Remove the return hose (5) at the reservoir (1). 8. Remove the return hose from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 6743 Power Steering Line/Hose: Service and Repair Power Steering Hose - Installation Pressure Hose PRESSURE HOSE 1. Install the pressure hose (4) to the vehicle. 2. Connect the pressure hose (4) at the pump pressure hose extension (6). Tighten the hose to 34 Nm (25 ft. lbs.). 3. Connect the pressure hose (4) at the gear. Tighten the hose to 37 Nm (27 ft. lbs.). 4. Connect the return hose (5) to the gear. Tighten the hose to 37 Nm (27 ft. lbs.). 5. Connect the pressure hose (4) to the retainer clip and the crossmember. 6. Install the inner wheel well See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation. NOTE: Before installing inner wheel well, verify that the hose is not touching other components. 7. Install the wheel and tire See: Wheels and Tires/Service and Repair/Removal and Replacement. 8. Remove the support and lower the vehicle. 9. Refill the power steering system See: Power Steering Fluid/Service and Repair. Return Hose RETURN HOSE 1. Install the return hose to the vehicle. 2. Connect the return hose (5) at the reservoir (1). 3. Connect the return hose (5) at the gear. Tighten the hose to 37 Nm (27 ft. lbs.). 4. Connect the return hose (5) to the retainer clip and the crossmember. NOTE: Before installing inner wheel well, verify that the hose is not touching other components. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Power Steering Hose - Removal > Page 6744 5. Install the inner wheel well. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation 6. Install the wheel and tire. See: Wheels and Tires/Service and Repair/Removal and Replacement 7. Remove the support and lower the vehicle. 8. Refill the power steering system See: Power Steering Fluid/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications Power Steering Pump: Specifications TORQUE NUMBER: Electric Power Steering (EPS) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6748 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Diagrams > Power Steering Pump Assembly C1 (HEV) (Headlamp And Dash) 2 Way Power Steering Pump: Diagrams Power Steering Pump Assembly C1 (HEV) (Headlamp And Dash) 2 Way Connector C1 (HEV) - (HEADLAMP AND DASH) 2 WAY ASSEMBLY-POWER STEERING PUMP (HEV) - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Diagrams > Power Steering Pump Assembly C1 (HEV) (Headlamp And Dash) 2 Way > Page 6751 Power Steering Pump: Diagrams Power Steering Pump Assembly C2 (HEV) (Headlamp And Dash) 3 Way Connector C2 (HEV) - (HEADLAMP AND DASH) 3 WAY ASSEMBLY-POWER STEERING PUMP (HEV) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Description and Operation > Power Steering Pump - Description Power Steering Pump: Description and Operation Power Steering Pump - Description Electric Power Steering (EPS) System ELECTRIC POWER STEERING (EPS) SYSTEM Power assist is provided by the EPS pump mounted to the Power Distribution Center (PDC). The EPS pump is an electrically operated hydraulic pump which supplies variable hydraulic fluid flow and pressure to the steering gear. The EPS pump replaces the conventional belted power steering pump and draws power from the 12V electrical system instead of the engine, reducing engine load. The EPS pump has an EPS module attached (not replaceable separately) for information processing and pump control for power steering assist. The EPS module monitors the vehicle Controller Area Network (CAN) communication system using information including vehicle speed, steering angle, and steering rate to calculate the steering assist required. The EPS Module does contain diagnostic functions. For descriptions and procedures related to DTCs See: Testing and Inspection. There are two electrical connectors on the EPS pump assembly. One connector is a 12V low amperage module connector, and the other is a 12V higher amperage (up to 98 amps) pump connector containing a larger gauge wire for motor operation. The power steering hoses and steering gear are substantially unchanged in function from a conventional system. However, there are unique components for this system, such as hoses for routing and the gear for valve tuning. This system requires no cooling system but it does monitor internal motor/fluid temperature. Electric Power Steering (EPS) Pump ELECTRIC POWER STEERING (EPS) PUMP NOTE: There is no internal service of the EPS pump. Replace the EPS pump as an assembly, including the reservoir, brackets and pressure hose extension. The EPS pump replaces the conventional belt-driven power steering pump and draws its power from the 12V electrical system instead of the engine crankshaft reducing engine load. The EPS pump mounts to bottom of PDC bracket with 2 studs and 1 bolt. Removal from the vehicle is possible through left front wheel opening after removing fender liner. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Description and Operation > Power Steering Pump - Description > Page 6754 Power Steering Pump: Description and Operation Power Steering Pump - Operation EPS System Operation EPS SYSTEM OPERATION The Electric Power Steering (EPS) Pump has different modes on which it will operate. A list of the modes follows: - Wake Up Mode - The EPS Pump control module initiates when ignition is in RUN or START positions. This begins start-up checks (memory checksums, internal sensors, faults etc.) and starts monitoring the vehicle CAN system. - Start Mode - The EPS module will start the electric pump motor to provide steering assist once one of the following occurs: Hybrid propulsion system active message is received (vehicle is started), or a vehicle speed message of greater than 3 mph (5 kp/h) is received. - The EPS Pump will then run until the ignition is turned off regardless of further changes in Hybrid Propulsion System or Vehicle Speed messages. There may be degraded assist during evasive maneuvers when there is no vehicle speed message. - Sleep Mode - If steering wheel is not moved for 5 seconds with vehicle speed less than 3 mph (5 kp/h) the pump will reduce output flow to 0.5 gm to minimize current consumption and heat buildup. Any steering wheel movement will return pump to normal operation. - End-lock Mode - If the steering wheel is held in lock (wheels to wheel stops) for 1 second or more with vehicle speed less than 12.5 mph (20 kp/h) the pump will reduce output flow to 0.5gmm to minimize current consumption and heat buildup. NOTE: Holding the steering wheel in the lock position for more than 3 seconds can damage the EPS system. - Shut Down Mode - At shutdown (loss of ignition signal to the module), the pump will: - Write any stored DTCs to EEPROM. - Shut down. Electric Power Steering (EPS) Pump ELECTRIC POWER STEERING (EPS) PUMP NOTE: If BOTH the Hybrid Propulsion System Active message (vehicle started) and Vehicle Speed Messages are missing at start-up, the EPS pump will remain in Wake Up Mode and will not operate. The EPS pump will start to provide steering assist when one of the following occurs: - A Hybrid Propulsion System Active message (vehicle started) is received. - A vehicle speed message of greater than 5 kp/h (3 mph) is received. After the pump starts: - If the Hybrid Propulsion System message is lost - the EPS pump will continue to run normally but will set a U0148 - Lost Communication with Hybrid Gateway Module DTC. - If the Vehicle Speed message is lost - the EPS pump will use a default vehicle speed of 85 kp/h (59 mph) to calculate desired flow and as a result, steering effort will no longer be speed sensitive. The EPS Module will set a U0121 Lost Communication with ABS DTC. - If the Steering Wheel Position message is lost - the EPS pump will use a default steering wheel rate of 230 deg/s to calculate desired flow and as a result, steering effort may be higher on evasive steering maneuvers. The EPS Module will set a U0126 - Lost Communication with Steering Angle Sensor DTC. - If the pump internal temperature exceeds 110° Celsius (230° F) the pump will begin to reduce output to self protect. - If the pump internal temperature exceeds 125° Celsius (257° F) internal temperature, the pump will shut off in order to self protect. The module will set a C1592 - Electronic Power Steering Motor Circuit DTC. - If the supply voltage drops below 9V or is above 16V, the EPS pump will shutoff to self protect. The EPS Module will set a C1588/C1589 - Power Steering Motor Inverter Power Supply High/Low DTC. The EPS pump will resume normal operation automatically once any missing message or out of range condition noted above is restored to normal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Pump Leakage Power Steering Pump: Testing and Inspection Pump Leakage PUMP LEAKAGE The pump is serviced as an assembly and should not be disassembled. The plastic pump reservoir and seal are not replaceable. If a leak exists in this area, replace the Electric Power Steering (EPS) pump. Check for leaks in the following areas: - Pump To Reservoir Seal - Pressure And Return Lines - Pressure Line Extension Fittings - Reservoir Cap Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Testing and Inspection > Pump Leakage > Page 6757 Power Steering Pump: Testing and Inspection Power Steering Pump and Hoses POWER STEERING PUMP AND HOSES NOTE: This information is designed to be used in conjunction with the diagnostic charts at the beginning of the Steering section. See: Testing and Inspection CHECKING FOR WEAR OF POWER STEERING PUMP INTERNAL COMPONENTS 1. Place gear selector in PARK (or NEUTRAL) with wheels chalked. 2. Using an electronic listening tool, determine if noise is coming from the pump. 3. NOTE: Some level of noise will be present and will change as load is increased. This is a normal condition. With the engine idling, have a helper turn the steering wheel. Does the noise change with load? 4. Replace the power steering pump if excessive noise is present. See: Service and Repair/Power Steering Pump - Removal CHECKING FOR POWER STEERING HOSES TOUCHING BODY OR FRAME OF VEHICLE Check hoses and hose tubes as following: - Inspect hoses and hose tubes for witness marks. If witness marks are present, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque See: Specifications. Do not bend tubing to adjust. Replace the hose assembly if damaged. - Check fastener torque of hose mounting brackets and tube nuts. See: Specifications - Have a helper bump the steering gear off of the stops to induce pressure fluctuations which may move the hose. If hose contact is made, adjust hose(s) to the proper position by loosening, repositioning and tightening attachments to the specified torque See: Specifications. Do not bend tubing to adjust. Replace the hose assembly if damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal Power Steering Pump: Service and Repair Power Steering Pump - Removal REMOVAL 1. Disconnect the 12 volt battery system ground isolation connector (1). 2. Siphon the fluid from the power steering pump. 3. Remove the power steering pump upper bracket (1) to Power Distribution Center (PDC) bracket (3) nuts (2). Allow the bracket to remain on the studs. 4. Raise and support the vehicle, See: Wheels and Tires/Vehicle Lifting/Service and Repair 5. Remove the left front wheel. 6. Remove the inner fender. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal > Page 6760 7. Remove the power steering pump electrical connectors (3). 8. Remove the return line (5) and disconnect the pressure line (4) at the extension fitting (6). 9. Remove the power steering pump lower mounting bolt (2). 10. Disengage the power steering bracket from the PDC bracket studs and remove the power steering pump (1) through the wheel well. 11. If replacing the pump pressure line extension fitting (6), remove the retaining bolt from the housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal > Page 6761 Power Steering Pump: Service and Repair Power Steering Pump - Installation INSTALLATION NOTE: Verify that the old pump pressure line extension fitting O-ring is removed and the new one is in place. 1. If replacing the pump pressure line extension fitting (6), install the fitting and the pressure line extension to pump bolt. Tighten the bolt to 20 Nm (15 ft. lbs.). 2. Through the wheel well, position the power steering pump upper bracket over the Power Distribution Center (PDC) bracket studs. 3. Install the power steering pump lower mounting bolt (2) through the power steering bracket to the PDC bracket. Tighten the bolt to 8 Nm (71 in lbs.). 4. Install the power steering return line (5) to the reservoir. 5. Install the power steering pressure line (4) to the pump pressure line extension fitting (6). Tighten the line to 34 Nm(25 ft. lbs.). 6. Connect the power steering pump electrical connectors (3). 7. Install the inner fender well. See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation 8. Install the wheel. See: Wheels and Tires/Service and Repair/Removal and Replacement 9. Remove the supports and lower the vehicle. 10. Install the power steering pump upper mounting bracket nuts (2) on the PDC bracket studs. Tighten the nuts to 10 Nm (88.5 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump - Removal > Page 6762 11. Connect the 12 volt battery system ground isolation connector (1). NOTE: The 5.7L HEV electric power steering (EPS) pump uses only Pentosan CHF 11S, Mopar(R) part number 05127381AA fluid. 12. Fill the power steering pump. See: Service and Repair Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications Steering Gear: Specifications TORQUE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Steering Gear - Description Steering Gear: Description and Operation Steering Gear - Description DESCRIPTION A rack and pinion steering gears is made up of two main components, the pinon shaft and the rack. Other components are the outer tie rod ends (3AND5), inner tie rods (1AND2), Mounting Bushings and the boots (4). The gear cannot be adjusted or internally serviced. If a malfunction or a fluid leak occurs, the gear must be replaced as an assembly. The only serviceable component on the steering gear is the outer tie rod ends (3AND5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Description and Operation > Steering Gear - Description > Page 6768 Steering Gear: Description and Operation Steering Gear - Operation OPERATION The steering column shaft is attached to the gear pinion. The rotation of the pinion moves the gear rack from side-to-side. This lateral action of the rack pushes and pulls the tie rods to change the direction of the front wheels. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal Steering Gear: Service and Repair Steering Gear - Removal REMOVAL 1. Siphon out as much power steering fluid as possible from the pump. 2. Center and lock the steering wheel. 3. Raise and support the vehicle, See: Wheels and Tires/Vehicle Lifting/Service and Repair. 4. Remove the front tires. 5. Remove the nuts (1) from the tie rod ends (3). 6. Separate tie rod ends (2) from the knuckles with Puller 8677 (1)See: Tie Rod/Tie Rod End/Service and Repair/Tie Rod End - Removal. 7. Remove the steering gear pinch bolt (2). 8. Remove the lower steering coupling (1) from the steering gear (3). NOTE: The tie rods would move to the left when turning the steering gear to the right. 9. Turn the steering gear to the full right position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 6771 10. Remove the exhaust Y-pipe (3) 3.7L AND 4.7L engines only. 11. Remove the power steering lines from the gear. See: Power Steering/Power Steering Line/Hose/Service and Repair/Power Steering Hose Removal , See: Power Steering/Power Steering Line/Hose/Service and Repair/Power Steering Hose - Removal. 12. Remove the front crossmember (2)See: Suspension/Cross-Member/Service and Repair/Crossmember - Removal. 13. Remove the steering gear mounting bolts (4), washers (5) and nuts (6). 14. Tip the gear (7) forward to allow clearance and move to the right then tip the gear downward on the left side to remove from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 6772 Steering Gear: Service and Repair Steering Gear - Installation INSTALLATION NOTE: Before installing gear inspect the bushings and replace if worn or damaged, also use new gear mounting bolts and nuts. 1. With the steering gear in the full right position (as in removal), install steering gear (7) to the vehicle and tighten the mounting nuts and bolts (4, 6) to 258 Nm (190 ft. lbs.). After tightening the fasteners, re-center the steering gear. 2. Install power steering lines to steering gear and tighten the pressure hose to 37 Nm (27 ft. lbs.) and tighten the return hose to 65 Nm (48 ft. lbs.). See: Power Steering/Power Steering Line/Hose/Service and Repair/Power Steering Hose Installation. CAUTION: The steering gear must be centered prior to installing the coupler to prevent clockspring damage. 3. Slide the shaft coupler (1) onto gear (3). Install a new lower pinch bolt (2) and tighten to 57 Nm (42 ft. lbs.). 4. Clean tie rod end studs and knuckle tapers (5). 5. Install tie rod ends (2) into the steering knuckles (5) and tighten the nuts (1) to 75 Nm (55 ft. lbs.). See: Tie Rod/Tie Rod End/Service and Repair/Tie Rod End - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and Repair > Steering Gear - Removal > Page 6773 6. Install the Y-pipe (3) 3.7L and 4.7L engines only. 7. Install the front crossmember (2) See: Suspension/Cross-Member/Service and Repair/Crossmember - Installation. 8. Install the front tires. 9. Remove the support and lower the vehicle. 10. Unlock the steering wheel. 11. Fill system with fluid, See: Service and Repair. 12. Adjust the toe position. See: Alignment/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal Steering Wheel: Service and Repair Removal REMOVAL 1. Disable and remove the driver's side airbag.See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag - Removal. 2. Partially remove the steering wheel bolt (2) and leave the bolt in the column. 3. Install puller CJ98-1(2) or equivalent using the top of the bolt to push on. 4. Remove and discard the steering wheel bolt (2). 5. Remove the steering wheel (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair > Removal > Page 6778 Steering Wheel: Service and Repair Installation INSTALLATION NOTE: Do not reuse the old steering wheel bolt (2) (a new bolt must be used) NOTE: Make sure to align the spline on the steering wheel hub to the column shaft. 1. Install steering wheel (1) to the column (4). NOTE: Be certain that the steering wheel mounting bolt is tightened to the proper torque specification to ensure proper clockspring operation. 2. Install the new steering wheel bolt (2). Tighten the bolt to 61 Nm (45 ft. lbs.). 3. Install the driver's side air bag to the steering wheel (1). See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection Tie Rod End: Testing and Inspection TIE ROD Tie rod free-play can be measured using the following hand methods: OUTER TIE ROD 1. Raise and support the vehicle. See: Wheels and Tires/Vehicle Lifting/Service and Repair. 2. Remove the front wheels. 3. Install two standard wheel mounting nuts, flat side to rotor, diagonally opposite to each on the rotor. 4. Attach a magnetic dial indicator (2) to the inside or outside of the brake rotor, then align the dial indicator's contact pointer (1) with the direction of the stud axis and touch the outer tie rod. 5. Zero the dial indicator. (3) NOTE: When checking free-play, DO NOT rotate the tie rod. Just because a tie rod rotates easily does not mean that it is necessarily faulty. Using more than light hand pressure will result in a false reading. 6. Grasp the outer tie rod near the ball stud and attempt to move the tie rod straight up and down using light hand pressure. (Less than 10 lbs. of force.) 7. Measure and record any tie rod free-play movement. 8. Remove the magnetic dial indicator. 9. Remove the standard wheel mounting nuts from the two studs. If the free-play in the tie rod exceeds 0.05 mm (.002 in.), replace the outer tie rod See: Service and Repair/Tie Rod End - Removal. If the free-play is less than 0.05 mm (.002 in.) at the outer tie rod check the inner tie rod for free-play. Refer to the following procedure. INNER TIE ROD Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Testing and Inspection > Page 6783 NOTE: Always check and repair (if necessary) outer tie rod free-play before checking inner tie rod free-play. False results can otherwise be obtained. 1. Grasp the inner tie rod near the steering gear bellows and attempt to move the tie rod straight up and down. If any free-play is felt, replace the inner tie rod See: Service and Repair/Tie Rod End - Removal. 2. If no free-play is felt, install the front wheels See: Wheels and Tires/Service and Repair/Removal and Replacement. 3. Remove support and lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal Tie Rod End: Service and Repair Tie Rod End - Removal Outer Tie Rod End OUTER TIE ROD END NOTE: Do not twist the boot anytime during removal or installation. 1. Loosen the jam nut (3). 2. Remove the outer tie rod end (2) nut (1) from the ball stud. 3. Separate the outer tie rod end (2) from the knuckle with Remover 8677 (1). 4. Unthread the outer tie rod end from the inner tie rod. Count the number of turns when removing the tie rod end, This will give a good starting point when reassembling and toe adjustment. Inner Tie Rod End INNER TIE ROD END Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal > Page 6786 1. Remove the outer tie rod end (1) Count the number of turns when removing, this will aid in setting the toe after installation.See: . 2. Remove the jam nut (3). 3. Remove the clamps (1) for the inner tie rod boot (2). 4. Remove the boot (2). 5. Install the special tool # 10087-3 socket (1) and # 10087-2 Tube (2) and remove the inner tie rod end. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal > Page 6787 Tie Rod End: Service and Repair Tie Rod End - Installation Outer Tie Rod End OUTER TIE ROD END NOTE: Do not twist the boot at anytime during removal or installation. 1. Thread the outer tie rod end (2) onto the inner tie rod (4), to it's original position. 2. Install the outer tie rod end into the steering knuckle (5). 3. Tighten the ball stud nut (1) on the ball stud to 75 Nm (55 ft. lbs.). 4. Set wheel toe pattern, See: Alignment/Service and Repair. 5. Tighten jam nut (3) to 109 Nm (80 ft. lbs.). Inner Tie Rod End INNER TIE ROD END 1. Thread the inner tie rod to the rack and pinion. 2. Tighten the inner tie rod end using special tool # 10087-3 socket (1) and # 10087-2 tube (2) to 169 Nm (125 ft.lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Tie Rod End - Removal > Page 6788 3. Install the inner tie rod end boot (2) and reclamp (1) to the tie rod (3) and rack. 4. Install the jam nut (1) to the inner tie rod end (2). 5. Install the outer tie rod (3) the same number of turns when removed See: . 6. Install the front wheels. 7. Lower the vehicle. 8. Perform toe adjustment. 9. Tighten the jam nut (1) after toe adjustment. Tighten to 50 Nm (37 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications Ball Joint: Specifications LOWER BALL JOINT If the travel exceeds 0.5 mm (0.020 in.), replace the lower ball joint. UPPER BALL JOINT If the travel exceeds 0.5 mm (0.020 in.), replace the upper control arm since the upper ball joint is integral to the arm. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Lower Ball Joint Ball Joint: Testing and Inspection Front Suspension Lower Ball Joint LOWER BALL JOINT NOTE: If the ball joint is equipped with a lubrication fitting, grease the joint then road test the vehicle before performing test. 1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. 2. Mount a dial indicator solidly to the top side of the lower control arm. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the steering knuckle. 3. Position the indicator plunger against the bottom surface of the steering knuckle, and then zero the dial indicator. 4. Position a pry bar under the tire assembly. Pry upwards on the tire assembly. 5. If the travel exceeds 0.5 mm (0.020 in.), replace the lower ball joint See: Service and Repair/Front Suspension Lower Ball Joint - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Front Suspension Lower Ball Joint > Page 6795 Ball Joint: Testing and Inspection Front Suspension Upper Ball Joint UPPER BALL JOINT 1. Raise the front of the vehicle. Place safety floor stands under both lower control arms as far outboard as possible. Lower the vehicle to allow the stands to support some or all of the vehicle weight. 2. Remove the front tires. 3. Mount a dial indicator (1) solidly to the frame. NOTE: The dial indicator plunger must be perpendicular to the machined surface of the ball joint. 4. Position dial indicator plunger on the topside of the upper ball joint (5), and then zero the dial indicator. NOTE: Use care not to pry or tear the ball joint boot, when checking the free play. 5. Position a pry bar (3) between the steering knuckle (4) and the upper control arm (2). Pry upwards on the upper control arm. 6. If the travel exceeds 0.5 mm (0.020 in.), replace the upper control arm since the upper ball joint is integral to the arm See: Control Arm/Service and Repair/Front Upper Control Arm - Removal. 7. If the upper ball joint is within specs reinstall the front tires See: Wheels and Tires/Service and Repair/Removal and Replacement. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Lower Ball Joint - Installation Ball Joint: Service and Repair Front Suspension Lower Ball Joint - Installation INSTALLATION NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 1. Install the ball joint (3) into the control arm and press in using special tools C-4212F (press) (1), 9333-1 (Receiver) (2) and 9333-3 (Driver) (4). 2. Stake the ball joint flange in four evenly spaced places around the ball joint flange, using a chisel and hammer. 3. Remove the support for the halfshaft and install into position 4X4 only. 4. Install the steering knuckle See: Front Steering Knuckle/Service and Repair/Front Steering Knuckle Installation. 5. Install the tie rod end into the steering knuckle See: Steering/Tie Rod/Tie Rod End/Service and Repair/Tie Rod End - Installation. 6. Install and tighten the halfshaft nut to 251 Nm (185 ft. lbs.). (If Equipped). 7. Install the brake caliper and rotor See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. 8. Install the tire and wheel assembly See: Wheels and Tires/Service and Repair/Removal and Replacement. 9. Check the vehicle ride height See: Alignment/Service and Repair. 10. Perform a wheel alignment See: Alignment/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Lower Ball Joint - Installation > Page 6798 Ball Joint: Service and Repair Front Suspension Lower Ball Joint - Removal REMOVAL 1. Remove the tire and wheel assembly. 2. Remove the brake caliper and rotor See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 3. Disconnect the tie rod (2) from the steering knuckle using puller 8677 (1)See: Steering/Tie Rod/Tie Rod End/Service and Repair/Tie Rod End Removal. 4. Separate the lower ball joint from the steering knuckle (1) using puller 8677 (2). 5. Remove the steering knuckle See: Front Steering Knuckle/Service and Repair/Front Steering Knuckle Removal. 6. Move the half shaft to the side and support the half shaft out of the way 4X4 only. 7. Chisel out the ball joint stakes. NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Front Suspension Lower Ball Joint - Installation > Page 6799 8. Press the ball joint from the lower control arm (3) using special tools C-4212F (PRESS) (1), 9333-1 (Driver) (2) and 9333-2 (Receiver) (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Lower Control Arm Bushings - Removal Control Arm Bushing: Service and Repair Front Lower Control Arm Bushings - Removal LOWER CONTROL ARM BUSHINGS 1. Remove the lower control arm See: Service and Repair/Front Lower Control Arm - Removal. 2. Secure the control arm in a vise. NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. LARGE BUSHING FRONT PART OF THE CONTROL ARM 1. Install the bushing tools C4212-F (Press)(1), (9334-4 (Driver)(2), 9334-6 (Spacer)(4) and 9334-5 (Receiver)(5) as shown for the replacement of the large bushing (3). SMALL BUSHING TORSION BAR SIDE 1. Install bushing remover tools C4212-F (Press)(1), 9334-4 (Driver)(2), 9334-6 (Spacer)(5) and 9334-5 (Receiver)(6) as shown for the small bushing (3) removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Front Lower Control Arm Bushings - Removal > Page 6805 Control Arm Bushing: Service and Repair Front Lower Control Arm Bushings - Installation LOWER CONTROL ARM BUSHINGS LARGE BUSHING FRONT PART OF THE CONTROL ARM NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 1. Install the new bushing (4) into the control arm (3) using special tools C4212-F (Press)(1), 9334-3 (Bushing installation depth spacer)(2), 9334-1 (driver)(5) as shown. SMALL BUSHING TORSION BAR SIDE 1. Install the new bushing (4) into the lower control arm (3) using tools C4212-F (Press)(1), 9334-3 (Bushing installation depth spacer), 9334-2 (Driver) as shown. 2. Remove the control arm from the vise. 3. Install the lower control arm See: Service and Repair/Front Lower Control Arm - Installation. 4. Reset the vehicle ride height See: Alignment/Service and Repair. 5. Perform a wheel alignment See: Alignment/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal Cross-Member: Service and Repair Crossmember - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the bolts (1) and nuts (3) and remove the crossmember (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 6810 Cross-Member: Service and Repair Crossmember - Installation INSTALLATION 1. Install the crossmember (2). 2. Install the bolts (1) and nuts (3). 3. Tighten the bolts and nuts to 102 Nm (75 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Front Knuckle - Description Front Steering Knuckle: Description and Operation Front Knuckle - Description DESCRIPTION The knuckle is a single casting with legs machined for the upper and lower ball joints. The knuckle also has machined mounting locations for the front brake calipers and hub bearing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Description and Operation > Front Knuckle - Description > Page 6815 Front Steering Knuckle: Description and Operation Front Knuckle - Operation OPERATION The steering knuckle pivot between the upper and lower ball joint. Steering linkage attached to the knuckle allows the vehicle to be steered. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal Front Steering Knuckle: Service and Repair Front Steering Knuckle - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, rotor See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal , shield and ABS wheel speed sensor if equipped See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor - Removal/Front. 4. Remove the front half shaft nut 4X4 only. 5. Remove the tie rod end nut. Separate the tie rod (2) from the knuckle with puller 8677 (1). CAUTION: When installing puller 8677 to separate the ball joint, be careful not to damage the ball joint seal. 6. Remove the upper ball joint nut. Separate the ball joint (1) from the knuckle (3) with Remover 8677 (2). 7. Install an hydraulic jack to support the lower control arm. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6818 8. Remove the lower ball joint nut. Separate the ball joint from the knuckle (1) with Remover 8677 (2) and remove the knuckle. 9. Remove the hub/bearing bolts (1) from the knuckle. 10. Remove the hub/bearing (4) from the steering knuckle (1) See: Wheel Bearing/Service and Repair/Front Hub and Bearing - Removal. 11. Remove the steering knuckle (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6819 Front Steering Knuckle: Service and Repair Front Steering Knuckle - Installation INSTALLATION CAUTION: The ball joint stud tapers must be CLEAN and DRY before installing the knuckle. Clean the stud tapers with mineral spirits to remove dirt and grease. 1. Install the hub/bearing to the steering knuckle and tighten the bolts (1) to 163 Nm (120 ft. lbs.). 2. Install the knuckle (1) onto the upper and lower ball joints. 3. Install the upper ball joint nut. Tighten the nut to 75 Nm (55 ft. lbs.). 4. Install the lower ball joint nut (3). Tighten the nut to 95 Nm (70 ft. lbs.). 5. Remove the hydraulic jack from the lower suspension arm (2). 6. Install the tie rod end and tighten the nut to 75 Nm (55 ft. lbs.). 7. Install the front halfshaft (2) into the hub/bearing 4X4 only. 8. Install the the halfshaft nut and tighten to 251 Nm (185 ft. lbs.) 4X4 only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair > Front Steering Knuckle - Removal > Page 6820 9. Install the ABS wheel speed sensor if equipped See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor - Installation/Front and brake shield, rotor and caliper See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. 10. Install the wheel and tire assembly See: Wheels and Tires/Service and Repair/Removal and Replacement. 11. Remove the support and lower the vehicle. 12. Perform a wheel alignment See: Alignment/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Rear Suspension Watts Link - Removal Lateral Stabilizer Rod: Service and Repair Rear Suspension Watts Link - Removal Bell Crank REMOVAL 1. Raise and support the vehicle. 2. Remove the watts link nuts (3) at the bell crank (5). 3. Remove both watts links (1) from the bell crank (5). 4. Remove the bell crank bolt (4) from the differential cover and remove the bell crank (5). Watts Link REMOVAL 1. Raise and support the vehicle. 2. Remove the upper nut (2) and bolt (2) to the watts link at the frame. 3. Remove the lower nut (3) to the watts link at the bell crank (5) and remove the watts link. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information > Service and Repair > Rear Suspension Watts Link - Removal > Page 6825 Lateral Stabilizer Rod: Service and Repair Rear Suspension Watts Link - Installation Bell Crank INSTALLATION 1. Install the bell crank (5) and bolt (4) to the differential cover and tighten 251 Nm (185 ft.lbs). 2. Install the watts links (1) and nuts (3) to the bell crank (5) and tighten 108 Nm (80 ft.lbs). 3. Lower the vehicle. Watts Link INSTALLATION 1. Install the watts link in position at the bell crank. 2. Install the watts links nuts (3) to the bell crank (5) and tighten 108 Nm (80 ft.lbs). 3. Install the watts link nut and bolt (2) at the frame and tighten 169 Nm (125 ft.lbs). 4. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Bar Link - Removal Stabilizer Link: Service and Repair Front Stabilizer Bar Link - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the lower nut (9). 3. Remove the upper nut, retainers and grommets from the stabilizer bar. 4. Remove the stabilizer link (7) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Bar Link - Removal > Page 6831 Stabilizer Link: Service and Repair Front Stabilizer Bar Link - Installation INSTALLATION 1. Install the stabilizer link (7) to the vehicle. 2. Install the retainers, grommets and upper nut to the stabilizer bar (6) and Tighten to 54 Nm (40 ft. lbs.). 3. Install the lower nut and Tighten to 169 Nm (125 ft. lbs.). 4. Remove the support and lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Bar Link - Removal > Page 6832 Stabilizer Link: Service and Repair Rear Suspension Stabilizer Bar Link - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the rear tire. 3. Support the rear axle with a jack. 4. Remove the fuel tank skid plate See: Body and Frame/Frame/Skid Plate/Service and Repair/Skid Plate - Removal. This step must be done for replacement of the left side stabilizer link. 5. Remove the rear fuel tank strap bolt and let the strap (4) hang. This step must be done for replacement of the left side stabilizer link. 6. Push the fuel tank (2) over towards the drive shaft (3) and install a block of wood (5) between the frame (6) and the fuel tank (2) to allow for clearance of the upper stabilizer link bolt (1). This step must be done for replacement of the left side stabilizer link. 7. Remove the upper link nut (2) and bolt (3) at the frame. 8. Remove the lower link nut (4) at the stabilizer bar (5). 9. Remove stabilizer link (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Stabilizer Bar Link - Removal > Page 6833 Stabilizer Link: Service and Repair Rear Suspension Stabilizer Bar Link - Installation INSTALLATION 1. Install the upper bolt (1) and nut (1) for the stabilizer link to the frame and tighten to 102 Nm (75 ft. lbs.). 2. Remove the block of wood (5) between the frame (6) and fuel tank (2). If replacement of left stabilizer link was performed. 3. Install the rear fuel tank strap (4). If replacement of left stabilizer link was performed. 4. Install the fuel tank skid plate See: Body and Frame/Frame/Skid Plate/Service and Repair/Skid Plate - Installation. If replacement of left stabilizer link was performed. 5. Install the stabilizer link (3) to the stabilizer bar (4). 6. Install the nut (5) and tighten to 102 Nm (75 ft. lbs.). 7. Remove the jack and lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Testing and Inspection Suspension Spring ( Coil / Leaf ): Testing and Inspection SPRING AND SHOCK A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock absorber must be replaced. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even. If the vehicle is used for severe, off-road operation, the springs should be examined periodically. Check for broken colis. Refer to Spring and Shock Absorber Diagnosis chart for additional information. SPRING AND SHOCK ABSORBER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear Suspension Coil Spring(s) - Removal Suspension Spring ( Coil / Leaf ): Service and Repair Rear Suspension Coil Spring(s) - Removal REMOVAL 1. Raise and support the vehicle. 2. Support the axle with a suitable holding fixture. 3. Remove the lower shock bolt. 4. Remove the bell crank bolt (4) to the rear axle. 5. Lower the jack to remove the spring and isolator from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear Suspension Coil Spring(s) - Removal > Page 6839 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Suspension Coil Spring(s) - Installation INSTALLATION NOTE: All torques should be made with the full vehicle weight on the ground being supported by the tires. 1. Position spring (3) to the vehicle on top of the isolator (2). 2. Align the springs (3) to the spring pockets. 3. Raise the rear axle into place. 4. Install the bell crank bolt (4) to the rear axle. Tighten to 251 Nm (185 ft. lbs.). 5. Install the lower shock bolts to the rear axle. Tighten to 102 Nm (75 ft. lbs.). 6. Remove the holding fixture for the rear axle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Shock Absorber Suspension Strut / Shock Absorber: Testing and Inspection Front Shock Absorber SHOCK A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock absorber must be replaced. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even. The shock absorber bushings do not require any type of lubrication. Do not attempt to stop bushing noise by lubricating them. Grease and mineral oil-base lubricants will deteriorate the bushing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Testing and Inspection > Front Shock Absorber > Page 6844 Suspension Strut / Shock Absorber: Testing and Inspection Rear Spring And Shock SPRING AND SHOCK A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching components. These noises can usually be stopped by tightening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attaching components. Repair as necessary if any of these conditions exist. A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent. This condition is not repairable and the shock absorber must be replaced. The shock absorbers are not refillable or adjustable. If a malfunction occurs, the shock absorber must be replaced. To test a shock absorber, hold it in an upright position and force the piston in and out of the cylinder four or five times. The action throughout each stroke should be smooth and even. If the vehicle is used for severe, off-road operation, the springs should be examined periodically. Check for broken colis. Refer to Spring and Shock Absorber Diagnosis chart for additional information. SPRING AND SHOCK ABSORBER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock Suspension Strut / Shock Absorber: Service and Repair Front Strut / Shock Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Support the lower control arm outboard end. 4. Remove the upper shock bolt (11) and nut (3). 5. Remove the stabilizer link (7) lower nut and then separate the stabilizer link from the lower control arm to gain access to the lower shock bolt (2) See: Stabilizer Bar/Stabilizer Link/Service and Repair/Front Stabilizer Bar Link - Removal. 6. Remove the lower shock bolt (2). 7. Remove the shock (1). Installation INSTALLATION 1. Install the upper part of the shock (1) into the frame bracket. 2. Install the nut (3) and bolt (11). Tighten to 102 Nm (75 ft. lbs.). 3. Install the lower part of the shock (1) into the lower control arm and Tighten the bolt (2) to 81 Nm (60 ft. lbs.). 4. Install the stabilizer link (7) lower nut to the lower control armSee: Stabilizer Bar/Stabilizer Link/Service and Repair/Front Stabilizer Bar Link Installation. 5. Remove the support from the lower control arm outboard end. 6. Install the tire and wheel assembly See: Wheels and Tires/Service and Repair/Removal and Replacement. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6847 7. Remove the support and lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Strut / Shock > Page 6848 Suspension Strut / Shock Absorber: Service and Repair Rear Shock Absorber Removal REMOVAL 1. Raise vehicle and support the axle. 2. Lower the spare tire This step must be done if replacing the left side shock. 3. Remove the upper shock bolt and flag nut. 4. Remove the lower shock bolt and nut. 5. Remove the rear shock absorber from the vehicle. Installation INSTALLATION 1. Position the shock absorber in the brackets. 2. Install the bolts through the brackets and the shock. Install the flag nut on the top bolt and nut on lower bolt. 3. Tighten the upper and lower bolt/nuts Tighten to 102 N.m (75 ft. lbs.) 4. Raise the spare tire back in place if lowered for the left shock. 5. Remove the support and lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Rear Suspension Jounce Bumper - Removal Suspension Travel Bumper: Service and Repair Rear Suspension Jounce Bumper - Removal REMOVAL 1. Raise and support the vehicle. NOTE: Rocking motion may be required while pulling the jounce bumper from the seating bracket 2. Twist and pull out the jounce bumper to remove the jounce bumper from the seating bracket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Service and Repair > Rear Suspension Jounce Bumper - Removal > Page 6853 Suspension Travel Bumper: Service and Repair Rear Suspension Jounce Bumper - Installation INSTALLATION 1. Install the jounce bumper and twist to seat in the bracket. 2. Remove the support and lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Description and Operation > Front Torsion Bar - Description Torsion Bar: Description and Operation Front Torsion Bar - Description DESCRIPTION The front of the bar connects to the back side of the lower suspension arm. The rear end of the bar is mounted in a anchor that rests in the frame crossmember. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Description and Operation > Front Torsion Bar - Description > Page 6858 Torsion Bar: Description and Operation Front Torsion Bar - Operation OPERATION The torsion bars are used to control ride height and ride quality. The vehicle height is adjusted through an anchor adjustment bolt that increases or decreases the wind up of the torsion bar. Increasing or decreasing the bar angle changes the wind up of the suspension arms. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Front Torsion Bar - Removal Torsion Bar: Service and Repair Front Torsion Bar - Removal REMOVAL CAUTION: The left and right side torsion bars are NOT interchangeable. The bars are identified and stamped R or L, for right or left. The bars do not have a front or rear end and can be installed with either end facing forward. 1. Raise and support the vehicle with the front suspension hanging. 2. Remove the transfer case skid plate See: Body and Frame/Frame/Skid Plate/Service and Repair/Skid Plate - Removal. NOTE: Count and record the number of turns for installation reference. 3. Mark the adjustment bolt setting. 4. Install loader/unloader tool 8686 (1) to the anchor arm (2) and the cross member (3). 5. Increase the tension on the anchor arm loader/unloader tool 8686 (1) until the load is removed from the adjustment bolt and the adjuster nut. 6. Turn the adjustment bolt counterclockwise to remove the bolt and the adjuster nut. 7. Remove the loader/unloader tool 8686 (1), allowing the torsion bar to unload. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Front Torsion Bar - Removal > Page 6861 Torsion Bar: Service and Repair Front Torsion Bar - Installation INSTALLATION CAUTION: The left and right side torsion bars are NOT interchangeable. The bars are identified and stamped R or L, for right or left. The bars do not have a front or rear end and can be installed with either end facing forward. 1. Insert torsion bar ends into anchor and suspension arm. 2. Position the anchor (2) in the crossmember frame (3). 3. Install loader/unloader tool 8686 (1) to the anchor (2) and the crossmember (3). 4. Increase the tension on the anchor in order to load the torsion bar. 5. Install the adjustment bolt and the adjuster nut. 6. Turn adjustment bolt clockwise the recorded amount of turns. 7. Remove the loader/unloader tool 8686 (1) from the torsion bar crossmember (3). 8. Install the transfer case skid plate See: Body and Frame/Frame/Skid Plate/Service and Repair/Skid Plate - Installation. 9. Lower vehicle and adjust the front suspension height See: Alignment/Service and Repair. 10. Perform a wheel alignment See: Alignment/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Front Torsion Bar - Removal > Page 6862 Torsion Bar: Service and Repair Front Suspension Torsion Bar Crossmember Bushing - Removal TORSION BAR CROSSMEMBER BUSHING 1. Remove the torsion bar cross member. 2. Secure the cross member in a vise. NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 3. Install special tools C4212-F (Press)(1), 9335-2 (Receiver)(4), 9335-3 (Driver)(2) and 9335-4 (Spacer)(3) as shown in the graphic. 4. Press out the bushing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Service and Repair > Front Torsion Bar - Removal > Page 6863 Torsion Bar: Service and Repair Front Suspension Torsion Bar Crossmember Bushing - Installation TORSION BAR CROSS MEMBER BUSHING NOTE: Extreme pressure lubrication must be used on the threaded portions of the tool. This will increase the longevity of the tool and insure proper operation during the removal and installation process. 1. Install the new bushing (3) into the cross member using special tools C4212-F (Press)(1), 9335-3(Driver)(2), 9335-4 (Spacer)(4) and 9335-1 (Depth setting cup)(5) making sure to properly orient the bushing. 2. Remove the cross member from the vise. 3. Install the torsion bar cross member. 4. Reset the vehicle ride height See: Alignment/Service and Repair. 5. Perform a wheel alignment See: Alignment/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Mopar Multi-Purpose Lube NLGI Grade 2 EP, GC-LB Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal Wheel Bearing: Service and Repair Front Hub and Bearing - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 4. Remove the ABS wheel speed sensor if equipped, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor - Removal/Front. 5. Remove the halfshaft nut 4X4 only. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod (2) from the knuckle using puller 8677 (1). 7. Remove the upper ball joint nut and separate the upper ball joint (1) from the knuckle (3) using puller 8677 (2). 8. Pull down on the steering knuckle to separate the half shaft from the hub/bearing. 4X4 only Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6869 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6870 Wheel Bearing: Service and Repair Front Hub and Bearing - Installation INSTALLATION 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. 4. Install the ABS wheel speed sensor (4) if equipped See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor - Installation/Front. 5. Install the upper ball joint nut to the steering knuckle and tighten to 75 Nm (55 ft. lbs.). 6. Install the tie rod end nut to the steering knuckle and tighten to 75 Nm (55 ft. lbs.). 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.) 4X4 only. 8. Install the wheel and tire assembly See: Wheels and Tires/Service and Repair/Removal and Replacement. 9. Remove the support and lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications AXLE NUT Half Shaft Nut....................................................................................................................................... ...................................................251 Nm (185 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Service and Repair Vehicle Lifting: Service and Repair HOISTING AND JACKING WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: The hoisting and jack lifting points provided are for a complete vehicle. When a chassis or drivetrain component is removed from a vehicle, the center of gravity is altered making some hoisting conditions unstable. Properly support or secure vehicle to hoisting device when these conditions exist. FLOOR JACKING Correct Vehicle Lifting Locations - Typical CAUTION: Do not attempt to lift a vehicle with a floor jack positioned under: an axle tube. - aluminum differential. - a body side sill. - a steering linkage component. - a drive shaft. - the engine or transmission oil pan. - the fuel tank. - a front suspension arm. When properly positioned, a floor jack can be used to lift a Durango vehicle. Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails. HOISTING A vehicle can be lifted with: - a single-post, frame contact hoist. - a twin-post, chassis hoist. - a ramp-type, drive on hoist. NOTE: When a frame contact type hoist is used, verify that the lifting pads are positioned properly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 6884 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 6885 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way Tire Pressure Monitor Receiver / Transponder: Diagrams Left Front Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT FRONT - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way > Page 6888 Tire Pressure Monitor Receiver / Transponder: Diagrams Left Rear Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT REAR - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way > Page 6889 Tire Pressure Monitor Receiver / Transponder: Diagrams Right Front Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-RIGHT FRONT - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Description DESCRIPTION PREMIUM SYSTEM A transponder, also known as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of the vehicle to provide the WCM/SKREEM with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description > Page 6892 Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Operation OPERATION NUMBER: PREMIUM SYSTEM On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (Each WCM cycle ends when the vehicle has been shut off for a time period of approximately 15 minutes or longer). Once the WCM has performed this to the three locations that have transponders (left front, right front, and left rear wheel wells), it uses the process-of-elimination theory to know that the fourth sensor ID signal is coming from the left rear tire sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Removal Front FRONT TRANSPONDER 1. Raise and support the vehicle. 2. Remove the wheel well housing cover (2). 3. Remove the mounting nut (1) for the transponder (2). 4. Disconnect the electrical connector and remove the transponder (2) from the vehicle. Rear REAR TRANSPONDER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 6895 1. Raise and support the vehicle. 2. Remove the mounting nut (1) for the transponder (2). 3. Disconnect the electrical connector (3) and remove the transponder (2) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 6896 Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Installation Front FRONT TRANSPONDER 1. Install the transponder (2) to the vehicle and reconnect the electrical connector. 2. Install the mounting nuts (1) for the transponder (2) Tighten to 3 Nm (25 in. lbs.). 3. Install the wheel well housing cover (2). 4. Lower the vehicle. Rear REAR TRANSPONDER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 6897 1. Install the transponder (2) to the vehicle and reconnect the electrical connector (3) and secure the harness to the stud (4). 2. Install the mounting nut (1) for the transponder (2). Tighten to 3 Nm (25 in. lbs.). 3. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The TPMS has been optimized for the original equipment tires and wheels. TPMS pressures have been established for the tire size equipped on your vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, and/or style. After-market wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with a TPMS, as damage to the sensors may result. NOTE: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Any time a sensor is to be reinstalled in a wheel, a new seal, cap and valve core must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION NOTE: On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 or 433 MHz radio frequency. The 315 MHz sensors can be easily identified by a black sensor body, with (an oval insignia) (1). The 433 MHz sensors can be identified by a grey sensor body with an oval insignia. NOTE: If replacing the WCM, the spare tire must be dismounted from its wheel to access and note the spare tire pressure sensor ID. Then follow the programming steps outlined in the diagnostic scan tool for "Learn Spare Tire Sensor ID" under Miscellaneous Functions for the WCM wireless control module menu item as appropriate. In addition, the placard pressure thresholds must be updated in the new WCM. Go to "Update Pressure Thresholds" under Miscellaneous Functions for the WCM wireless control module and follow the procedure. On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a black sensor body, with (an oval insignia) (1) and a grey valve cap (2). The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by a gray sensor body (with an oval insignia) and a black valve cap (2). CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Domestic vehicles, use the 315 MHz TPM sensors with the BLACK sensor body. For Export vehicles, use the 433 MHz TPM sensors with the GREY sensor body. Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct color sensor is being used. A RKE-TPM Analyzer can be used to determine the sensor's frequency without having to dismount the tire. NOTE: If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel. (This could cause sealing and system performance issues). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor Description > Page 6904 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (4) - Valve Stem Cap (2) - Valve Stem Core - Valve Stem Nut (3) The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor Description > Page 6905 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit if using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor's operating mode and to diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following modes: - Sleep Mode - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. - Park Mode - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 PSI delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure 30 Block Mode - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to Park Mode using a TPM-RKE Analyzer, the sensor's operating mode will transition from Park Mode to 30 Block Mode once the vehicle is driven over 15mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 8 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to Drive Mode - Drive Mode - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time that the vehicle speed drops below 15mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h). If the vehicle has been stationary for more then 20 minutes, the TPM sensor will change to PARK MODE. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 m.p.h. (24 Km/h)" after a sensor has been replaced, The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The sensor IDs can also be programmed using the TPM-RKE Analyzer Tool. Scan each TPM sensor at each road wheel, and store each Sensor ID in the correct location. (LEFT FRONT, LEFT REAR, RIGHT FRONT, and RIGHT REAR) Connect the TPM-RKE Analyzer Tool to the Scan Tool. Then follow the programming steps outlined in the diagnostic Scan Tool for "Program Tire Pressure Sensor ID w/ TPM Tool" under "MISC" for the "WCM/WIRELESS CONTROL MODULE". Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6908 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6909 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 6 Nm (53 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6910 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the outer and inner tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. 8. Remove the support and lower the vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6911 b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Indicator - Description Low Tire Pressure Indicator: Description and Operation Low Tire Pressure Indicator - Description DESCRIPTION A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the speedometer dial face to the left of the speedometer needle hub in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Indicator - Description > Page 6917 Low Tire Pressure Indicator: Description and Operation Low Tire Pressure Indicator - Operation OPERATION The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM), over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position, the SKREEM sends an electronic TPM indicator lamp-on message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Indicator Lamp-On Message - Each time the cluster receives an electronic TPM indicator lamp-on message from the SKREEM, the TPM indicator illuminates. The indicator can be flashed on and off, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a lamp-off message from the SKREEM or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-on or lamp-off messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-on or lamp-off message is received from the SKREEM. - Self Test - Each time the cluster is put through the self test, the TPM indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the ON position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or low. The SKREEM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the instrument cluster turns on the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is ineffective. Use a diagnostic scan tool for proper diagnosis of the TPM system, the SKREEM, the CCN, the CAN data bus or the electronic communication related to TPM indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 6922 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 6923 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way Tire Pressure Monitor Receiver / Transponder: Diagrams Left Front Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT FRONT - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way > Page 6926 Tire Pressure Monitor Receiver / Transponder: Diagrams Left Rear Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT REAR - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way > Page 6927 Tire Pressure Monitor Receiver / Transponder: Diagrams Right Front Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-RIGHT FRONT - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Description DESCRIPTION PREMIUM SYSTEM A transponder, also known as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of the vehicle to provide the WCM/SKREEM with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description > Page 6930 Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Operation OPERATION NUMBER: PREMIUM SYSTEM On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (Each WCM cycle ends when the vehicle has been shut off for a time period of approximately 15 minutes or longer). Once the WCM has performed this to the three locations that have transponders (left front, right front, and left rear wheel wells), it uses the process-of-elimination theory to know that the fourth sensor ID signal is coming from the left rear tire sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Removal Front FRONT TRANSPONDER 1. Raise and support the vehicle. 2. Remove the wheel well housing cover (2). 3. Remove the mounting nut (1) for the transponder (2). 4. Disconnect the electrical connector and remove the transponder (2) from the vehicle. Rear REAR TRANSPONDER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 6933 1. Raise and support the vehicle. 2. Remove the mounting nut (1) for the transponder (2). 3. Disconnect the electrical connector (3) and remove the transponder (2) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 6934 Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Installation Front FRONT TRANSPONDER 1. Install the transponder (2) to the vehicle and reconnect the electrical connector. 2. Install the mounting nuts (1) for the transponder (2) Tighten to 3 Nm (25 in. lbs.). 3. Install the wheel well housing cover (2). 4. Lower the vehicle. Rear REAR TRANSPONDER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 6935 1. Install the transponder (2) to the vehicle and reconnect the electrical connector (3) and secure the harness to the stud (4). 2. Install the mounting nut (1) for the transponder (2). Tighten to 3 Nm (25 in. lbs.). 3. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The TPMS has been optimized for the original equipment tires and wheels. TPMS pressures have been established for the tire size equipped on your vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, and/or style. After-market wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with a TPMS, as damage to the sensors may result. NOTE: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Any time a sensor is to be reinstalled in a wheel, a new seal, cap and valve core must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION NOTE: On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 or 433 MHz radio frequency. The 315 MHz sensors can be easily identified by a black sensor body, with (an oval insignia) (1). The 433 MHz sensors can be identified by a grey sensor body with an oval insignia. NOTE: If replacing the WCM, the spare tire must be dismounted from its wheel to access and note the spare tire pressure sensor ID. Then follow the programming steps outlined in the diagnostic scan tool for "Learn Spare Tire Sensor ID" under Miscellaneous Functions for the WCM wireless control module menu item as appropriate. In addition, the placard pressure thresholds must be updated in the new WCM. Go to "Update Pressure Thresholds" under Miscellaneous Functions for the WCM wireless control module and follow the procedure. On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a black sensor body, with (an oval insignia) (1) and a grey valve cap (2). The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by a gray sensor body (with an oval insignia) and a black valve cap (2). CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Domestic vehicles, use the 315 MHz TPM sensors with the BLACK sensor body. For Export vehicles, use the 433 MHz TPM sensors with the GREY sensor body. Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct color sensor is being used. A RKE-TPM Analyzer can be used to determine the sensor's frequency without having to dismount the tire. NOTE: If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel. (This could cause sealing and system performance issues). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 6941 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (4) - Valve Stem Cap (2) - Valve Stem Core - Valve Stem Nut (3) The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 6942 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit if using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor's operating mode and to diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following modes: - Sleep Mode - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. - Park Mode - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 PSI delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure 30 Block Mode - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to Park Mode using a TPM-RKE Analyzer, the sensor's operating mode will transition from Park Mode to 30 Block Mode once the vehicle is driven over 15mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 8 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to Drive Mode - Drive Mode - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time that the vehicle speed drops below 15mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h). If the vehicle has been stationary for more then 20 minutes, the TPM sensor will change to PARK MODE. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 m.p.h. (24 Km/h)" after a sensor has been replaced, The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The sensor IDs can also be programmed using the TPM-RKE Analyzer Tool. Scan each TPM sensor at each road wheel, and store each Sensor ID in the correct location. (LEFT FRONT, LEFT REAR, RIGHT FRONT, and RIGHT REAR) Connect the TPM-RKE Analyzer Tool to the Scan Tool. Then follow the programming steps outlined in the diagnostic Scan Tool for "Program Tire Pressure Sensor ID w/ TPM Tool" under "MISC" for the "WCM/WIRELESS CONTROL MODULE". Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6945 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6946 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 6 Nm (53 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6947 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the outer and inner tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. 8. Remove the support and lower the vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 6948 b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tires Tires: Description and Operation Tires TIRES Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe brake applications - High speed driving - Excessive speeds on turns - Striking curbs and other obstacles Radial-ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval See: Service and Repair/Procedures. This will help to achieve a greater tread life. TIRE IDENTIFICATION Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code. Performance tires have a speed rating letter after the aspect ratio number. The speed rating is not always printed on the tire sidewall. These ratings are: - Q up to 99 mph - S up to 112 mph - T up to 118 mph - U up to 124 mph - H up to 130 mph - V up to 149 mph - W (consult the tire manufacturer for the specific speed rating) - Z more than 149 mph (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M AND S or M-S (indicating mud and snow traction) imprinted on the side wall. TIRE CHAINS Tire snow chains may be used on certain models. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 6953 Tires: Description and Operation Radial - Ply Tires RADIAL-PLY TIRES Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance. Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary. A maximum speed of 80 KPH (50 MPH) is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could also cause inaccurate wheel speed signals when the vehicle is equipped with Anti-Lock Brakes. The use of tires from different manufactures on the same vehicle is NOT recommended. The proper tire pressure should be maintained on all four tires. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 6954 Tires: Description and Operation Tire Pressure for High Speeds TIRE PRESSURE FOR HIGH SPEED Refer to the Vehicles Owners Manual package. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 6955 Tires: Description and Operation Tire Inflation Pressures TIRE INFLATION PRESSURES WARNING: Over or under inflated tires can affect vehicle handling and tread wear. This may cause the tire to fail suddenly, resulting in loss of vehicle control. Under inflation will cause rapid shoulder wear (1), tire flexing, and possible tire failure. Over inflation will cause rapid center wear (1) reduction in the tire's ability to cushion shocks. Improper inflation can cause: - Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride - Vehicle drift For proper tire pressure specification refer to the tire label placard usually located on the drivers door latch pillar. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 6956 Tires: Description and Operation Tires TIRES Tires are designed and engineered for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicle's requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain in most cases, much greater mileage than severe use or careless drivers. A few of the driving habits which will shorten the life of any tire are: - Rapid acceleration - Severe brake applications - High speed driving - Excessive speeds on turns - Striking curbs and other obstacles Radial-ply tires are more prone to irregular tread wear. It is important to follow the tire rotation interval See: Service and Repair/Procedures. This will help to achieve a greater tread life. TIRE IDENTIFICATION Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code. Performance tires have a speed rating letter after the aspect ratio number. The speed rating is not always printed on the tire sidewall. These ratings are: - Q up to 99 mph S up to 112 mph T up to 118 mph - U up to 124 mph - H up to 130 mph - V up to 149 mph - W (consult the tire manufacturer for the specific speed rating) - Z more than 149 mph (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M AND S or M-S (indicating mud and snow traction) imprinted on the side wall. TIRE CHAINS Tire snow chains may be used on certain models. Radial - Ply Tires RADIAL-PLY TIRES Radial-ply tires improve handling, tread life and ride quality, and decrease rolling resistance. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 6957 Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary. A maximum speed of 80 KPH (50 MPH) is recommended while a temporary spare is in use. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They also use the same recommended inflation pressures. The use of oversized tires, either in the front or rear of the vehicle, can cause vehicle drive train failure. This could also cause inaccurate wheel speed signals when the vehicle is equipped with Anti-Lock Brakes. The use of tires from different manufactures on the same vehicle is NOT recommended. The proper tire pressure should be maintained on all four tires. Tire Pressure for High Speeds TIRE PRESSURE FOR HIGH SPEED Refer to the Vehicles Owners Manual package. Tire Inflation Pressures TIRE INFLATION PRESSURES WARNING: Over or under inflated tires can affect vehicle handling and tread wear. This may cause the tire to fail suddenly, resulting in loss of vehicle control. Under inflation will cause rapid shoulder wear (1), tire flexing, and possible tire failure. Over inflation will cause rapid center wear (1) reduction in the tire's ability to cushion shocks. Improper inflation can cause: - Uneven wear patterns - Reduced tread life - Reduced fuel economy - Unsatisfactory ride Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Description and Operation > Tires > Page 6958 - Vehicle drift For proper tire pressure specification refer to the tire label placard usually located on the drivers door latch pillar. Spare / Temporary Tire SPARE / TEMPORARY TIRE The temporary spare tire is designed for emergency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 80 KMH (50 MPH). when using the temporary spare tire. Full Size Spare Wheel With Matching Tire FULL SIZE, SPARE WHEEL WITH MATCHING TIRE The spare is a full usage wheel with a matching tire. It can be used within the (posted legal) speed limits or distance limitations as of the rest of the vehicles four tires. Replacement Tires REPLACEMENT TIRES The original equipment tires provide a proper balance of many characteristics such as: - Ride - Noise - Handling - Durability - Tread life - Traction - Rolling resistance - Speed capability It is recommended that tires equivalent to the original equipment tires be used when replacement is needed. Failure to use equivalent replacement tires may adversely affect the safety and handling of the vehicle. The use of oversize tires may cause interference with vehicle components. Under extremes of suspension and steering travel, interference with vehicle components may cause tire damage. WARNING: Failure to equip the vehicle with tires having adequate speed capability can result in sudden tire failure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges Tires: Testing and Inspection Pressure Gauges PRESSURE GAUGES A quality air pressure gauge is recommended to check tire pressure. After checking the air pressure, replace valve cap finger tight. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 6961 Tires: Testing and Inspection Tire Wear Patterns TIRE WEAR PATTERNS Under inflation will cause wear on the shoulders of tire. Over inflation will cause wear at the center of tire. Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the other. Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 6962 Tires: Testing and Inspection Tire/Vehicle Lead TIRE/VEHICLE LEAD Use the following Vehicle Lead Diagnosis And Correction Chart to diagnose and correct a vehicle lead or drift problem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 6963 Tires: Testing and Inspection Tread Wear Indicators TREAD WEAR INDICATORS Tread wear indicators (3) are molded into the bottom of the tread grooves. When tread depth is 1.6 mm (1/16 in.), the tread wear indicators (3) will appear as a 13 mm (1/2 in.) band. Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Testing and Inspection > Pressure Gauges > Page 6964 Tires: Testing and Inspection Tire Noise Or Vibration TIRE NOISE OR VIBRATION Radial-ply tires are sensitive to force impulses caused by improper mounting, vibration, wheel defects, or possibly tire imbalance. To find out if tires are causing the noise or vibration, drive the vehicle over a smooth road at varying speeds. Note the noise level during acceleration and deceleration. The engine, differential and exhaust noises will change as speed varies, while the tire noise will usually remain constant. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures Tires: Procedures CLEANING Remove the protective coating on the tires before delivery of a vehicle. This coating may cause deterioration of the tires. To remove the protective coating, apply warm water and let it soak for a few minutes. Afterwards, scrub the coating away with a soft bristle brush. Steam cleaning may also be used to remove the coating. NOTE: DO NOT use gasoline, mineral oil, oil-based solvent or a wire brush for cleaning. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Procedures > Page 6967 Tires: Removal and Replacement TIRE REPAIR AREA For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the defect, or puncture, is in the tread area (1). The tire should be replaced if the puncture is located in the sidewall. Deflate tire completely before removing the tire from the wheel. Use lubrication such as a mild soap solution when dismounting or mounting tire. Use tools free of burrs or sharp edges which could damage the tire or wheel rim. Before mounting tire on wheel, make sure all rust is removed from the rim bead and repaint if necessary. Install wheel on vehicle, and tighten to proper torque specification. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information Wheels: Technical Service Bulletins Wheels/Tires - Chrome Clad Wheel Balancing Information NUMBER: 22-002-09 GROUP: Wheels/Tires DATE: July 29, 2009 SUBJECT: Chrome Clad Wheel Adapters For Proper Balancing OVERVIEW: This bulletin describes the use of proper wheel adapters when mounting Chrome Clad wheels to wheel balancing equipment. MODELS: 2004-2008 (CS) Pacifica 2007 - 2009 (D1) Ram Truck (3500 Pick Up) 2007 - 2010 DC) Ram Truck (3500 Chassis Cab) 2005 - 2009 (DH) Ram Truck (1500/2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2004 - 2009 (HB) Durango 2007-2009 (HG) Aspen 2009-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2008 - 2010 (JS27) Sebring Convertible 2007 - 2010 (JS41) Sebring/Avenger 2007-2010 (KA) Nitro 2002-2007 (KJ) Liberty 2002 - 2007 (KJ) Cherokee (International Markets) 2008 - 2010 (KK) Liberty 2009 - 2010 (LC) Challenger 2005 - 2010 (LE) 300C/300C Touring (International Markets) 2005 - 2010 (LX) 300/Magnum/Charger 2007 - 2010 (MK) Compass/Patriot 2005-2010 (ND) Dakota 2007 - 2001 (PM) Caliber 2001 - 2009 (PT) Chrysler PT Cruiser 2001 - 2007 (RG) Chrysler Voyager (International Markets) 2001 - 2007 (RS) Town & Country/Caravan/Voyager 2008 - 2010 (RI) Town & Country/Grand Caravan Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Wheels/Tires - Chrome Clad Wheel Balancing Information > Page 6972 2008 - 2010 (RI) Town & Country/Grand Voyager (International Markets) 2005 - 2010 (WH) Grand Cherokee (International Markets) 2005-2010 (WK) Grand Cherokee 2006 - 2010 (XH) Commander (International Markets) 2006 - 2010 (XK) Commander NOTE: This information applies to any model equipped with Chrome Clad Wheels. DISCUSSION: Models equipped with Chrome Clad wheels require specific piloting on balance equipment to properly center the wheel and prevent damage to the chrome clad surface. The chrome cladding is not removable or replaceable and has cladding tabs that extend into the wheel bore. Traditional high-taper cones will come into contact with the cladding tabs rather than properly seat on the hub bore chamfer. Many modern aluminum wheel designs cannot be mounted with traditional cones. Direct-Fit Collets should be used to properly mount clad wheels on balance equipment (Fig 1). SPECIAL TOOLS/EQUIPMENT REQUIRED: NOTE: This kit includes the adapters for all Dodge, Chrysler & Jeep models with clad wheels. Individual adapters for specific wheel sizes can be ordered separately. To order a kit or individual adapters, contact Pentastar Service Equipment @ 1-800-223-5623. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6973 Wheels: Description and Operation DESCRIPTION The rim size is on the vehicle safety certification label located on the drivers door shut face. Original equipment wheels/rims are designed for operation up to the specified maximum vehicle capacity. All models use stamped steel, cast aluminum or forged aluminum wheels. Every wheel has raised sections between the rim flanges (1) and rim drop well (3) called safety humps. Initial inflation of the tire forces the bead over these raised sections. In case of rapid loss of air pressure, the raised sections help hold the tire on the wheel. The wheel studs and nuts are designed for specific applications. All aluminum and some steel wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary to ensure proper retention of the wheels. Do not use replacement studs or nuts with a different design or lesser quality. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 6974 Wheels: Testing and Inspection WHEEL INSPECTION Inspect wheels for: - Excessive run out - Dents or cracks - Damaged wheel lug nut holes - Air Leaks from any area or surface of the rim NOTE: Do not attempt to repair a wheel by hammering, heating or welding. If a wheel is damaged an original equipment replacement wheel should be used. When obtaining replacement wheels, they should be equivalent in load carrying capacity. The diameter, width, offset, pilot hole and bolt circle of the wheel should be the same as the original wheel. WARNING: Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehicle. Used wheels are not recommended. The service history of the wheel may have included severe treatment or very high mileage. The rim could fail without warning. WARNING: Chrysler LLC does not recommend that customers use "reconditioned" wheels (wheels that have been damaged and repaired) because they can result in a sudden catastrophic wheel failure which could cause loss of control and result in injury or death. For Clarification: - Cosmetic refinishing for the purpose of repairing a superficial flaw is an acceptable procedure providing it is limited to paint or clear coat only, the wheel is not modified in any way, and there is no exposure to paint curing heat over 200 degrees Fahrenheit. - Damaged wheels are those which have been bent, broken, cracked or sustained some other physical damage which may have compromised the wheel structure - Repaired indicates that the wheel has been modified through bending, welding, heating, straightening, or material removal to rectify damage. - Re-plating of chrome plated wheels is not an acceptable procedure nor is chrome plating of original equipment painted or polished wheels, as this may alter mechanical properties and affect fatigue life. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Mopar Multi-Purpose Lube NLGI Grade 2 EP, GC-LB Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal Wheel Bearing: Service and Repair Front Hub and Bearing - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper and rotor See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 4. Remove the ABS wheel speed sensor if equipped, See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor - Removal/Front. 5. Remove the halfshaft nut 4X4 only. NOTE: Do not strike the knuckle with a hammer to remove the tie rod end or the ball joint. Damage to the steering knuckle will occur. 6. Remove the tie rod end nut and separate the tie rod (2) from the knuckle using puller 8677 (1). 7. Remove the upper ball joint nut and separate the upper ball joint (1) from the knuckle (3) using puller 8677 (2). 8. Pull down on the steering knuckle to separate the half shaft from the hub/bearing. 4X4 only Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6980 9. Remove the three hub/bearing mounting bolts (1) from the steering knuckle. 10. Slide the hub/bearing out of the steering knuckle. 11. Remove the brake dust shield. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Hub and Bearing - Removal > Page 6981 Wheel Bearing: Service and Repair Front Hub and Bearing - Installation INSTALLATION 1. Install the brake dust shield (2). 2. Install the hub/bearing (1) into the steering knuckle (3) and tighten the bolts (5) to 163 Nm (120 ft. lbs.). 3. Install the brake rotor and caliper See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. 4. Install the ABS wheel speed sensor (4) if equipped See: Brakes and Traction Control/Antilock Brakes / Traction Control Systems/Wheel Speed Sensor/Service and Repair/Wheel Speed Sensor - Installation/Front. 5. Install the upper ball joint nut to the steering knuckle and tighten to 75 Nm (55 ft. lbs.). 6. Install the tie rod end nut to the steering knuckle and tighten to 75 Nm (55 ft. lbs.). 7. Install the halfshaft nut and tighten to 251 Nm (185 ft. lbs.) 4X4 only. 8. Install the wheel and tire assembly See: Service and Repair/Removal and Replacement. 9. Remove the support and lower vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications AXLE NUT Half Shaft Nut....................................................................................................................................... ...................................................251 Nm (185 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications Wheel Lug Nut...................................................................................................................................... ...............................190 ± 13.5 Nm (140 ± 10 ft. lbs.) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal Wheel Fastener: Service and Repair Wheel Stud - Removal Front FRONT 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 4. Remove the wheel speed sensor from the hub. 5. Press the stud from the hub using remover C-4150A (1). 6. Remove the stud (2) from the hub (1) through the backing plate access hole (3). Rear REAR Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 6991 1. Raise and support the vehicle, See: Vehicle Lifting/Service and Repair. 2. Remove the wheel and tire assembly. 3. Remove the brake caliper, caliper adapter and rotor, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Removal. 4. Using appropriate tools, remove the spring (3) at parking brake adjuster (2). 5. Spread the parking brake shoes (1) apart enough to remove the adjuster (may need to back off adjustment), then remove the adjuster (2). 6. Rotate the axle around until the wheel stud (1) lines up with the opening where the adjuster was removed. 7. Press the stud (1) from the hub using Ball Joint Press C-4150A (3). 8. Remove the stud (1) from the rear of the hub flange. It may be necessary to work the hub flange back and forth to ease stud removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 6992 Wheel Fastener: Service and Repair Wheel Stud - Installation Front FRONT 1. Install the new stud (2) into the hub flange (1). 2. Install three proper sized washers onto the stud, then install lug nut with the flat side of the nut against the washers. 3. Tighten the lug nut until the stud is pulled into the hub flange. Verify that the stud is properly seated into the flange. 4. Remove the lug nut and washers. 5. Install the brake rotor, caliper adapter, and caliper, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. 6. Install the wheel speed sensor. 7. Install the wheel and tire assembly, use new lug nut on the stud or studs that were replaced. 8. Remove the support and lower the vehicle. Rear REAR 1. Install the new stud (4) into the hub flange (2) at the opening where the adjuster was removed. 2. Install three proper sized washers (1) onto the new stud (4), then install a lug nut (3) with the flat side of the nut against the washers. 3. Tighten the lug nut (3) until the stud (4) is pulled into the hub flange (2). Verify that the stud is properly seated into the flange. 4. Remove the lug nut (3) and washers (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Wheel Stud - Removal > Page 6993 5. Install the parking brake adjuster (2) between the parking brake shoes (1) with the adjuster star wheel near the adjustment window in the brake shield. 6. Using appropriate tools, install the spring (3) at the adjuster (2). 7. Adjust parking brake shoes as necessary, See: Brakes and Traction Control/Parking Brake System/Parking Brake Shoe/Adjustments. 8. Install the brake rotor, caliper adapter and caliper, See: Brakes and Traction Control/Disc Brake System/Brake Rotor/Disc/Service and Repair/Removal and Replacement/Brake Rotor - Installation. 9. Using a new lug nut on the new stud, install the wheel and tire assembly, See: Service and Repair/Removal and Replacement. 10. Remove the supports and lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 7000 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 7001 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 7002 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 7003 Air Door Actuator / Motor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 7004 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 7005 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 7006 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 7007 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 7008 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Left Blend Door Actuator > Page 7009 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (HVAC) 2 Way Air Door Actuator / Motor: Diagrams Left Blend Door Actuator (HVAC) 2 Way Connector - (HVAC) 2 WAY ACTUATOR-BLEND DOOR-LEFT - (HVAC) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (HVAC) 2 Way > Page 7012 Air Door Actuator / Motor: Diagrams Rear Blend Door Actuator (HVAC) 6 Way Connector - (HVAC) 6 WAY ACTUATOR-BLEND DOOR-REAR - (HVAC) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (HVAC) 2 Way > Page 7013 Air Door Actuator / Motor: Diagrams Right Blend Door Actuator (Dual Zone) (HVAC) 2 Way Connector (DUAL ZONE) - (HVAC) 2 WAY ACTUATOR-BLEND DOOR-RIGHT (DUAL ZONE) - (HVAC) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (HVAC) 2 Way > Page 7014 Air Door Actuator / Motor: Diagrams Front Floor To Defrost Mode Door Actuator (HVAC) 2 Way Connector - (HVAC) 2 WAY ACTUATOR-MODE DOOR-FLOOR TO DEFROST-FRONT - (HVAC) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (HVAC) 2 Way > Page 7015 Air Door Actuator / Motor: Diagrams Left Blend Door Actuator (HVAC) 2 Way Connector - (HVAC) 2 WAY ACTUATOR-BLEND DOOR-LEFT - (HVAC) 2 WAY Rear Blend Door Actuator (HVAC) 6 Way Connector - (HVAC) 6 WAY ACTUATOR-BLEND DOOR-REAR - (HVAC) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (HVAC) 2 Way > Page 7016 Right Blend Door Actuator (Dual Zone) (HVAC) 2 Way Connector (DUAL ZONE) - (HVAC) 2 WAY ACTUATOR-BLEND DOOR-RIGHT (DUAL ZONE) - (HVAC) 2 WAY Front Floor To Defrost Mode Door Actuator (HVAC) 2 Way Connector - (HVAC) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (HVAC) 2 Way > Page 7017 ACTUATOR-MODE DOOR-FLOOR TO DEFROST-FRONT - (HVAC) 2 WAY Front Floor To Panel Mode Door Actuator (HVAC) 2 Way Connector - (HVAC) 2 WAY ACTUATOR-MODE DOOR-FLOOR TO PANEL-FRONT - (HVAC) 2 WAY Rear Mode Door Actuator (HVAC) 6 Way Connector - (HVAC) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams > Left Blend Door Actuator (HVAC) 2 Way > Page 7018 ACTUATOR-MODE DOOR-REAR - (HVAC) 6 WAY Recirculation Door Actuator (HVAC) 2 Way Connector - (HVAC) 2 WAY ACTUATOR-RECIRCULATION DOOR - (HVAC) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description Air Door Actuator / Motor: Description and Operation Blend Door Actuator - Description Front DESCRIPTION Models with the single zone heating-A/C system have a single blend-air door, which is controlled by a single blend door actuator (1). Models with the dual zone system have two blend-air doors, which are controlled by two blend door actuators. The blend door actuators are reversible, 12-volt direct current (DC), servo motors. The blend door actuator for the single zone heating-A/C system is located on top of the HVAC housing, behind the dash panel. For the dual zone heating-A/C system, the same blend door actuator used for the single zone system becomes the passenger side blend door actuator, which is mechanically connected to only the passenger side blend-air door. A second separate blend door actuator located on the bottom of the HVAC housing is mechanically connected to the driver side blend-air door. The blend door actuators are interchangeable with the actuators for both mode-air doors and the recirculation-air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Three integral mounting tabs allow the actuator to be secured to the HVAC housing. Each actuator also has an identical output shaft with splines that connects it to a blend-air door. The blend door actuators do not require mechanical indexing to the blend-air doors, as they are electronically calibrated by the A/C-heater control. Rear DESCRIPTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 7021 The rear blend door actuator (1) is a reversible, 12 volt direct current (DC), servo motor. The rear blend door actuator is located on the inboard side of the rear heater-A/C housing. The rear blend door actuator is contained within a black molded plastic housing which has an integral wire connector receptacle (2), three integral mounting tabs (4) and an output shaft with splines (3) that connect the actuator to the rear blend-air door. The rear blend door actuator is interchangeable with the actuator for the mode-air door. The rear blend door actuator does require mechanical indexing to the rear blend-air door, as it is electronically calibrated by the A/C-heater control. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 7022 Air Door Actuator / Motor: Description and Operation Blend Door Actuator - Operation Front OPERATION The blend door actuators are connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the HVAC wire harness. The blend door actuator(s) can move the blend-air door(s) in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the blend-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the blend-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the blend-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the blend door actuator(s) and the blend-air door(s). The A/C-heater control learns the blend-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the blend door actuator circuits. The blend door actuators are diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The blend door actuators cannot be adjusted or repaired and must be replaced if inoperative or damaged. Rear OPERATION The rear blend door actuator is connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the rear heater-A/C wire harness. The rear blend door actuator can move the rear blend-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the rear blend-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the rear blend-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the rear blend-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the rear blend door actuator and the rear blend-air door. The A/C-heater control learns the rear blend-air door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the rear blend door actuator circuit. The rear blend door actuator is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear blend door actuator cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 7023 Air Door Actuator / Motor: Description and Operation Mode Door Actuator - Description Front DESCRIPTION The two mode door actuators (floor/defrost and panel door) (1) are reversible, 12-volt direct current (DC), servo motors. Both mode door actuators are located near the drivers side end of the HVAC housing. The mode door actuators are mechanically connected to the floor/defrost and the panel-air door. Both mode door actuators are interchangeable with each other and with the actuators for the blend-air door and the recirculation-air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Three integral mounting tabs allow the actuator to be secured to the top of the HVAC housing. Each actuator also has an identical output shaft with splines that connects it to the mode-air doors. The mode door actuators do not require mechanical indexing to the mode-air doors, as they are electronically calibrated by the A/C-heater control. Rear DESCRIPTION The rear mode door actuator (1) is a reversible, 12 volt direct current (DC), servo motor. The rear mode door actuator is located on the inboard side of the rear heater-A/C housing. The rear mode door actuator is contained within a black molded plastic housing which has an integral wire connector receptacle (2), three integral mounting tabs (4) and an output shaft with splines (3) that connect the actuator to the rear mode-air door. The rear mode door actuator is interchangeable with the actuator for the blend-air door. The rear mode door actuator does require mechanical indexing to the rear mode-air door, as it is electronically calibrated by the A/C-heater control. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 7024 Air Door Actuator / Motor: Description and Operation Mode Door Actuator - Operation Front OPERATION The floor/defrost and panel (mode) door actuators are connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the HVAC wire harness. The mode door actuators can move the floor/defrost and the panel-air doors in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the mode-air door(s) will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the mode-air door(s) moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the mode-air door(s) stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the floor/defrost and panel door actuators and the mode-air doors. The A/C-heater control learns the mode-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the mode door actuator circuits. The mode door actuators are diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The mode door actuators cannot be adjusted or repaired and must be replaced if inoperative or damaged. Rear OPERATION The rear mode door actuator is connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the rear heater-A/C wire harness. The rear mode door actuator can move the rear model-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the rear mode-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the rear mode-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the rear mode-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the rear mode door actuator and the rear mode-air door. The A/C-heater control learns the rear mode-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the rear mode door actuator circuit. The rear mode door actuators are diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear mode door actuator cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 7025 Air Door Actuator / Motor: Description and Operation Front DESCRIPTION Models with the single zone heating-A/C system have a single blend-air door, which is controlled by a single blend door actuator (1). Models with the dual zone system have two blend-air doors, which are controlled by two blend door actuators. The blend door actuators are reversible, 12-volt direct current (DC), servo motors. The blend door actuator for the single zone heating-A/C system is located on top of the HVAC housing, behind the dash panel. For the dual zone heating-A/C system, the same blend door actuator used for the single zone system becomes the passenger side blend door actuator, which is mechanically connected to only the passenger side blend-air door. A second separate blend door actuator located on the bottom of the HVAC housing is mechanically connected to the driver side blend-air door. The blend door actuators are interchangeable with the actuators for both mode-air doors and the recirculation-air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Three integral mounting tabs allow the actuator to be secured to the HVAC housing. Each actuator also has an identical output shaft with splines that connects it to a blend-air door. The blend door actuators do not require mechanical indexing to the blend-air doors, as they are electronically calibrated by the A/C-heater control. Rear DESCRIPTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 7026 The rear blend door actuator (1) is a reversible, 12 volt direct current (DC), servo motor. The rear blend door actuator is located on the inboard side of the rear heater-A/C housing. The rear blend door actuator is contained within a black molded plastic housing which has an integral wire connector receptacle (2), three integral mounting tabs (4) and an output shaft with splines (3) that connect the actuator to the rear blend-air door. The rear blend door actuator is interchangeable with the actuator for the mode-air door. The rear blend door actuator does require mechanical indexing to the rear blend-air door, as it is electronically calibrated by the A/C-heater control. Front OPERATION The blend door actuators are connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the HVAC wire harness. The blend door actuator(s) can move the blend-air door(s) in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the blend-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the blend-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the blend-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the blend door actuator(s) and the blend-air door(s). The A/C-heater control learns the blend-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the blend door actuator circuits. The blend door actuators are diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The blend door actuators cannot be adjusted or repaired and must be replaced if inoperative or damaged. Rear OPERATION The rear blend door actuator is connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the rear heater-A/C wire harness. The rear blend door actuator can move the rear blend-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the rear blend-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the rear blend-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the rear blend-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the rear blend door actuator and the rear blend-air door. The A/C-heater control learns the rear blend-air door stop positions during the calibration procedure and will store a Diagnostic Trouble Code (DTC) for any problems it detects in the rear blend door actuator circuit. The rear blend door actuator is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear blend door actuator cannot be adjusted or repaired and must be replaced if inoperative or damaged. Front DESCRIPTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 7027 The two mode door actuators (floor/defrost and panel door) (1) are reversible, 12-volt direct current (DC), servo motors. Both mode door actuators are located near the drivers side end of the HVAC housing. The mode door actuators are mechanically connected to the floor/defrost and the panel-air door. Both mode door actuators are interchangeable with each other and with the actuators for the blend-air door and the recirculation-air door. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Three integral mounting tabs allow the actuator to be secured to the top of the HVAC housing. Each actuator also has an identical output shaft with splines that connects it to the mode-air doors. The mode door actuators do not require mechanical indexing to the mode-air doors, as they are electronically calibrated by the A/C-heater control. Rear DESCRIPTION The rear mode door actuator (1) is a reversible, 12 volt direct current (DC), servo motor. The rear mode door actuator is located on the inboard side of the rear heater-A/C housing. The rear mode door actuator is contained within a black molded plastic housing which has an integral wire connector receptacle (2), three integral mounting tabs (4) and an output shaft with splines (3) that connect the actuator to the rear mode-air door. The rear mode door actuator is interchangeable with the actuator for the blend-air door. The rear mode door actuator does require mechanical indexing to the rear mode-air door, as it is electronically calibrated by the A/C-heater control. Front OPERATION The floor/defrost and panel (mode) door actuators are connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the HVAC wire harness. The mode door actuators can move the floor/defrost and the panel-air doors in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the mode-air door(s) will move in one Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 7028 direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the mode-air door(s) moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the mode-air door(s) stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the floor/defrost and panel door actuators and the mode-air doors. The A/C-heater control learns the mode-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the mode door actuator circuits. The mode door actuators are diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The mode door actuators cannot be adjusted or repaired and must be replaced if inoperative or damaged. Rear OPERATION The rear mode door actuator is connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the rear heater-A/C wire harness. The rear mode door actuator can move the rear model-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the rear mode-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the rear mode-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the rear mode-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the rear mode door actuator and the rear mode-air door. The A/C-heater control learns the rear mode-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the rear mode door actuator circuit. The rear mode door actuators are diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear mode door actuator cannot be adjusted or repaired and must be replaced if inoperative or damaged. Recirculation Door Actuator - Description DESCRIPTION The recirculation door actuator (1) is a reversible, 12 volt direct current (DC), servo motor. The recirculation door actuator is located on the left side of the HVAC air inlet housing. The recirculation door actuator is interchangeable with the actuators for the blend-air door and the mode-air doors. Each actuator is contained within an identical black molded plastic housing with an integral wire connector receptacle. Three integral mounting tabs allow the actuator to be secured to the air inlet housing. Each actuator also has an identical output shaft with splines that connects it to the recirculation-air door. The recirculation door actuator does not require mechanical indexing to the recirculation-air door, as it is electronically calibrated by the A/C-heater control. Recirculation Door Actuator - Operation OPERATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Description and Operation > Blend Door Actuator - Description > Page 7029 The recirculation door actuator is connected to the A/C-heater control through the vehicle electrical system by a dedicated two-wire lead and connector of the HVAC wire harness. The recirculation door actuator can move the recirculation-air door in two directions. When the A/C-heater control pulls the voltage on one side of the motor connection high and the other connection low, the recirculation-air door will move in one direction. When the A/C-heater control reverses the polarity of the voltage to the motor, the recirculation-air door moves in the opposite direction. When the A/C-heater control makes the voltage to both connections high or both connections low, the recirculation-air door stops and will not move. The A/C-heater control uses a pulse-count positioning system to monitor the operation and relative position of the recirculation door actuator and the recirculation-air door. The A/C-heater control learns the recirculation-air door stop positions during the calibration procedure and will store a diagnostic trouble code (DTC) for any problems it detects in the recirculation door actuator circuits. The recirculation door actuator is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The recirculation door actuator cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal Air Door Actuator / Motor: Service and Repair Blend Door Actuator - Removal Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door. SINGLE ZONE/DUAL ZONE PASSENGER SIDE 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 3. Remove the three screws (4) that secure the blend door actuator (2) to the top of the HVAC housing (3). 4. Remove the blend door actuator from the HVAC housing and disconnect the HVAC wire harness connector (1) from the actuator. DUAL ZONE DRIVER SIDE 1. Disconnect and isolate the negative battery cable. 2. Remove the three screws (1) that secure the blend door actuator and cover (2) to the bottom of the HVAC housing (3) below the glove box. 3. Remove the blend door actuator and cover from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7032 Rear REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove right rear quarter panel trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the rear heater-A/C wire harness connector (2) from the rear blend door actuator. 4. Remove the two screws (4) that secure the rear blend door actuator (1) to the inboard side of the rear heater-A/C housing (3) and remove the actuator. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7033 Air Door Actuator / Motor: Service and Repair Blend Door Actuator - Installation Front INSTALLATION NOTE: The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door. SINGLE ZONE/DUAL ZONE PASSENGER SIDE 1. Position the blend door actuator (1) to the top of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the blend-air door linkage (4). 2. Install the three screws (4) that secure the blend door actuator (2) to the top of the HVAC housing (3). Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the HVAC wire harness connector (1) to the blend door actuator. 4. Install the instrument panel assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Installation. 5. Reconnect the negative battery cable. 6. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. DUAL ZONE DRIVER SIDE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7034 1. Position the blend door actuator (1) to the bottom of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the blend-air door linkage (4). 2. Install the three screws (1) that secure the blend door actuator and cover (2) to the bottom of the HVAC housing (3). Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the HVAC wire harness connector (1) to the blend door actuator. Make sure the wire harness is properly secured to the bottom of the HVAC housing. 4. Reconnect the negative battery cable. 5. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Rear INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7035 1. Position the rear blend door actuator (1) onto the inboard side of the rear heater-A/C housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the rear actuator coupler (4). 2. Install the two screws (4) that secure the rear blend door actuator (1) to the rear heater-A/C housing (3). Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the rear heater-A/C wire harness connector (2) to the rear blend door actuator. 4. Install the right rear quarter panel trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 5. Reconnect the negative battery cable. 6. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. 7. Verify that the Actuator Calibration of the front A/C-heater control has passed. If an Actuator Calibration has not passed, correct any errors before proceeding. 8. Rotate the Rear Temperature Selector counter (1) clockwise to the Cold Position. Allow the Selector to remain in the Cold Position for 5 seconds. 9. Rotate the Rear Temperature Selector Clockwise to the Hot Position. Allow the Selector to remain in the Cold Position for 5 seconds. 10. Calibration is now complete. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7036 Air Door Actuator / Motor: Service and Repair Mode Door Actuator - Removal Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the screws (5) that secure the panel door actuator (2) and the floor/defrost door actuator (3) located on the driver side end of the HVAC housing (4) as required. 3. Disconnect the HVAC wire harness connector (1) from the panel door actuator and the floor/defrost door actuator as required. 4. Remove the mode door actuator(s) from the HVAC housing. Rear REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove right rear quarter panel trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the rear heater-A/C wire harness connector (1) from the rear mode door actuator (4) located on the inboard side of the rear heater-A/C housing (3). 4. Remove the two screws (2) that secure the rear mode door actuator to the rear heater-A/C housing and remove the actuator. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7037 Air Door Actuator / Motor: Service and Repair Mode Door Actuator - Installation Front INSTALLATION 1. Position the mode door actuator(s) (1) onto the driver side end of the HVAC housing as required. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode-air door linkage. 2. Install the screws (5) that secure the panel door actuator (2) and the floor/defrost door actuator (3) to the HVAC housing (4) as required. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the HVAC wire harness connector (1) to the mode door actuator(s) as required. 4. Reconnect the negative battery cable. 5. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Rear INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7038 1. Position the rear mode door actuator (1) onto the inboard side of the rear heater-A/C housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (4) with those in the actuator coupler (3). 2. Install the screws (2) that secure the rear mode door actuator (4) to the rear heater-A/C housing (3). Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the rear heater-A/C wire harness connector (1) to the rear mode door actuator. 4. Reconnect the negative battery cable. 5. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. 6. Verify that the Actuator Calibration of the front A/C-heater control has passed. If an Actuator Calibration has not passed, correct any errors before proceeding. 7. Rotate the Rear Temperature Selector counter (1) clockwise to the Cold Position. Allow the Selector to remain in the Cold Position for 5 seconds. 8. Rotate the Rear Temperature Selector Clockwise to the Hot Position. Allow the Selector to remain in the Cold Position for 5 seconds. 9. Calibration is now complete. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7039 Air Door Actuator / Motor: Service and Repair Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door. SINGLE ZONE/DUAL ZONE PASSENGER SIDE 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 3. Remove the three screws (4) that secure the blend door actuator (2) to the top of the HVAC housing (3). 4. Remove the blend door actuator from the HVAC housing and disconnect the HVAC wire harness connector (1) from the actuator. DUAL ZONE DRIVER SIDE 1. Disconnect and isolate the negative battery cable. 2. Remove the three screws (1) that secure the blend door actuator and cover (2) to the bottom of the HVAC housing (3) below the glove box. 3. Remove the blend door actuator and cover from the HVAC housing and disconnect the HVAC wire harness connector (4) from the actuator. Rear Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7040 REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove right rear quarter panel trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the rear heater-A/C wire harness connector (2) from the rear blend door actuator. 4. Remove the two screws (4) that secure the rear blend door actuator (1) to the inboard side of the rear heater-A/C housing (3) and remove the actuator. Front INSTALLATION NOTE: The single zone heating-A/C system is equipped with a single blend door actuator. The dual zone system has two blend door actuators, one for the driver side blend-air door and one for the passenger side blend-air door. SINGLE ZONE/DUAL ZONE PASSENGER SIDE 1. Position the blend door actuator (1) to the top of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the blend-air door linkage (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7041 2. Install the three screws (4) that secure the blend door actuator (2) to the top of the HVAC housing (3). Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the HVAC wire harness connector (1) to the blend door actuator. 4. Install the instrument panel assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Installation. 5. Reconnect the negative battery cable. 6. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. DUAL ZONE DRIVER SIDE 1. Position the blend door actuator (1) to the bottom of the HVAC housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the blend-air door linkage (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7042 2. Install the three screws (1) that secure the blend door actuator and cover (2) to the bottom of the HVAC housing (3). Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the HVAC wire harness connector (1) to the blend door actuator. Make sure the wire harness is properly secured to the bottom of the HVAC housing. 4. Reconnect the negative battery cable. 5. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Rear INSTALLATION 1. Position the rear blend door actuator (1) onto the inboard side of the rear heater-A/C housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (3) with those on the rear actuator coupler (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7043 2. Install the two screws (4) that secure the rear blend door actuator (1) to the rear heater-A/C housing (3). Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the rear heater-A/C wire harness connector (2) to the rear blend door actuator. 4. Install the right rear quarter panel trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 5. Reconnect the negative battery cable. 6. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. 7. Verify that the Actuator Calibration of the front A/C-heater control has passed. If an Actuator Calibration has not passed, correct any errors before proceeding. 8. Rotate the Rear Temperature Selector counter (1) clockwise to the Cold Position. Allow the Selector to remain in the Cold Position for 5 seconds. 9. Rotate the Rear Temperature Selector Clockwise to the Hot Position. Allow the Selector to remain in the Cold Position for 5 seconds. 10. Calibration is now complete. Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the screws (5) that secure the panel door actuator (2) and the floor/defrost door actuator (3) located on the driver side end of the HVAC housing (4) as required. 3. Disconnect the HVAC wire harness connector (1) from the panel door actuator and the floor/defrost door actuator as required. 4. Remove the mode door actuator(s) from the HVAC housing. Rear Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7044 REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove right rear quarter panel trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the rear heater-A/C wire harness connector (1) from the rear mode door actuator (4) located on the inboard side of the rear heater-A/C housing (3). 4. Remove the two screws (2) that secure the rear mode door actuator to the rear heater-A/C housing and remove the actuator. Front INSTALLATION 1. Position the mode door actuator(s) (1) onto the driver side end of the HVAC housing as required. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode-air door linkage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7045 2. Install the screws (5) that secure the panel door actuator (2) and the floor/defrost door actuator (3) to the HVAC housing (4) as required. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the HVAC wire harness connector (1) to the mode door actuator(s) as required. 4. Reconnect the negative battery cable. 5. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Rear INSTALLATION 1. Position the rear mode door actuator (1) onto the inboard side of the rear heater-A/C housing (2). If necessary, rotate the actuator slightly to align the splines on the actuator output shaft (4) with those in the actuator coupler (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7046 2. Install the screws (2) that secure the rear mode door actuator (4) to the rear heater-A/C housing (3). Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the rear heater-A/C wire harness connector (1) to the rear mode door actuator. 4. Reconnect the negative battery cable. 5. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. 6. Verify that the Actuator Calibration of the front A/C-heater control has passed. If an Actuator Calibration has not passed, correct any errors before proceeding. 7. Rotate the Rear Temperature Selector counter (1) clockwise to the Cold Position. Allow the Selector to remain in the Cold Position for 5 seconds. 8. Rotate the Rear Temperature Selector Clockwise to the Hot Position. Allow the Selector to remain in the Cold Position for 5 seconds. 9. Calibration is now complete. Recirculation Door Actuator - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the HVAC assembly See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal. 3. Remove the air inlet housing (1) from the HVAC housing and place it on a workbench See: Housing Assembly HVAC/Service and Repair/Overhaul/Disassembly/Front HVAC Housing. 4. Remove the screws (2) that secure the recirculation door actuator (3) to the HVAC air inlet housing. 5. Remove the recirculation door actuator from the HVAC air inlet housing. Recirculation Door Actuator - Installation INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Blend Door Actuator - Removal > Page 7047 1. Position the recirculation door actuator (1) to the HVAC air inlet housing. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the recirculation-air door linkage. 2. Install the screws (2) that secure the recirculation door actuator (3) to the HVAC air inlet housing (1). Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the air inlet housing to the HVAC housing See: Housing Assembly HVAC/Service and Repair/Overhaul/Assembly/Front HVAC Housing. 4. Install the HVAC housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Installation. 5. Reconnect the negative battery cable. 6. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal Air Duct: Service and Repair Defroster Duct - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage. 1. Remove the instrument panel and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 2. Remove the two screws (1) that secure the defroster duct (2) to the top of the instrument panel (3). 3. Remove the two screws (1) that secure the defroster duct (2) to the instrument panel wire harness support (3). 4. Remove the defroster duct from the instrument panel (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7052 Air Duct: Service and Repair Defroster Duct - Installation INSTALLATION 1. Position the defroster duct (2) into the instrument panel (4). 2. Install the two screws (1) that secure the defroster duct to the instrument panel wire harness support (3). Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the two screws (1) that secure the defroster duct (2) to the top of the instrument panel (3). Tighten the screws to 2 Nm (17 in. lbs.). 4. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7053 Air Duct: Service and Repair Center Distribution Duct - Removal REMOVAL 1. Remove the instrument panel and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 2. Remove the defroster duct See: Defroster Duct - Removal. 3. Remove the demister ducts See: Instrument Panel Demister Duct - Removal. 4. Remove the two screws (1) that secure the center distribution duct (2) to the instrument panel support. 5. Disconnect the center distribution duct from the instrument panel duct (3) and remove the center duct. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7054 Air Duct: Service and Repair Center Distribution Duct - Installation INSTALLATION 1. Connect the center distribution duct (2) to the instrument panel duct (3). 2. Install the two screws (1) that secure the center distribution duct to the instrument panel support. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the demister ducts See: Instrument Panel Demister Duct - Installation. 4. Install the defroster duct See: Defroster Duct - Installation. 5. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7055 Air Duct: Service and Repair Defroster Duct - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage. 1. Remove the instrument panel and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 2. Remove the two screws (1) that secure the defroster duct (2) to the top of the instrument panel (3). 3. Remove the two screws (1) that secure the defroster duct (2) to the instrument panel wire harness support (3). 4. Remove the defroster duct from the instrument panel (4). Defroster Duct - Installation INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7056 1. Position the defroster duct (2) into the instrument panel (4). 2. Install the two screws (1) that secure the defroster duct to the instrument panel wire harness support (3). Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the two screws (1) that secure the defroster duct (2) to the top of the instrument panel (3). Tighten the screws to 2 Nm (17 in. lbs.). 4. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. Center Distribution Duct - Removal REMOVAL 1. Remove the instrument panel and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7057 and Repair/Instrument Panel - Removal. 2. Remove the defroster duct See: Defroster Duct - Removal. 3. Remove the demister ducts See: Instrument Panel Demister Duct - Removal. 4. Remove the two screws (1) that secure the center distribution duct (2) to the instrument panel support. 5. Disconnect the center distribution duct from the instrument panel duct (3) and remove the center duct. Center Distribution Duct - Installation INSTALLATION 1. Connect the center distribution duct (2) to the instrument panel duct (3). 2. Install the two screws (1) that secure the center distribution duct to the instrument panel support. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the demister ducts See: Instrument Panel Demister Duct - Installation. 4. Install the defroster duct See: Defroster Duct - Installation. 5. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. Front REMOVAL FRONT FLOOR DISTRIBUTION DUCT 1. Remove the HVAC Housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal. 2. Remove the six screws (1) that secure the front floor distribution duct (2) to the bottom of the HVAC housing (3). 3. Remove the front floor distribution duct from the HVAC housing. INTERMEDIATE FLOOR DISTRIBUTION DUCTS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7058 1. Remove the center floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Removal. 2. Remove the front seats See: Body and Frame/Seats/Service and Repair/Seat, Front/Seat - Removal. 3. Roll back the front floor carpet from under the instrument panel toward the rear of the vehicle See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Carpet - Removal. 4. Remove the two push pin fasteners (1) that secure the right intermediate floor distribution duct (2) and the left intermediate floor distribution duct (3) to the floor support (4). 5. Disconnect the left intermediate floor distribution duct from the front floor distribution duct (5). 6. If required, disconnect the right intermediate floor distribution duct from the left intermediate floor distribution duct. Rear REMOVAL 1. Remove the right interior quarter panel trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 2. Remove the push-pin fasteners (1) that secure the rear ceiling distribution duct (2) and the rear floor distribution duct (3) to the right interior quarter panel (4). 3. Disconnect the rear ceiling distribution duct from the rear heater-A/C housing (5) by sliding the lower half of the ceiling distribution duct into the upper half of the ceiling distribution duct. 4. Disconnect the rear ceiling distribution duct from the headliner duct and remove the ceiling distribution duct from the vehicle. 5. Disconnect the rear floor distribution duct from the rear heater-A/C housing and remove the floor distribution duct from the vehicle. Front INSTALLATION FRONT FLOOR DISTRIBUTION DUCT Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7059 1. Position the front floor distribution duct (2) to the bottom of the HVAC housing (3). 2. Install the six screws (1) that secure the front floor distribution duct to the HVAC housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the HVAC housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Installation. INTERMEDIATE FLOOR DISTRIBUTION DUCTS 1. If removed, connect the right intermediate floor distribution duct (2) to the left intermediate floor distribution duct (3). 2. Connect the left intermediate floor distribution duct to the front floor distribution duct (5). 3. Install the two push-pin fasteners (1) that secure the intermediate floor distribution ducts to the floor support (4). 4. Install the carpet onto the front floor panel and under the instrument panel See: Body and Frame/Interior Moulding / Trim/Carpet/Service and Repair/Carpet - Installation. 5. Install the front seats See: Body and Frame/Seats/Service and Repair/Seat, Front/Seat Installation. 6. Install the center floor console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Installation. Rear INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7060 1. Connect the rear floor distribution duct (3) to the rear heater-A/C housing (5). 2. Connect the rear ceiling distribution duct (2) to the headliner duct and the rear heater-A/C housing. Make sure that the rear ceiling distribution duct is fully installed to ensure a good seal. 3. Install the push-pin fasteners (1) that secure the rear ceiling distribution duct and the rear floor distribution duct to the right interior quarter panel (4). 4. Install the right interior quarter panel trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. Instrument Panel Duct - Removal REMOVAL NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage. 1. Remove the instrument panel and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 2. Remove the instrument panel top cover. 3. Remove the defroster duct (1) See: Defroster Duct Removal. 4. Remove the two screws (3) that secure the instrument panel wire harness (4) to the instrument panel support (5). 5. Remove the demister ducts (2 and 6) See: Instrument Panel Demister Duct - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7061 6. Remove the two screws (1) that secure the center distribution duct (2) to the instrument panel support. 7. Disconnect the center distribution duct from the instrument panel duct (3) and remove the center duct. 8. Remove the two screws (1) that secure the driver side/center instrument panel duct (7) to the rear of the instrument panel support (2). 9. Remove the four screws (4) that secure the passenger instrument panel duct (3) to the instrument panel front cover (5). 10. Remove the two screws (6) that secure the driver side/center instrument panel duct to the instrument panel front cover. 11. Remove the instrument panel ducts from the instrument panel as an assembly. Tilt and rotate the ducts as necessary. 12. Separate the passenger side instrument panel duct from the driver side/center instrument panel duct. Instrument Panel Duct - Installation INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7062 1. Install the passenger side instrument panel duct (3) onto the driver/center instrument panel duct (7). Make sure the ducts are fully engaged to each other. 2. Install the instrument panel ducts onto the instrument panel as an assembly. Make sure the center duct outlets are fully engaged into the instrument panel front cover (5). 3. Install the two screws (6) that secure the driver side/center instrument panel duct to the instrument panel front cover. Tighten the screws to 2 Nm (17 in. lbs.). 4. Install the four screws (4) that secure the passenger instrument panel duct to the instrument panel front cover. Tighten the screws to 2 Nm (17 in. lbs.). 5. Install the two screws (1) that secure the driver side/center instrument panel duct to the rear of the instrument panel support (2). Tighten the screws to 2 Nm (17 in. lbs.). 6. Connect the center distribution duct (2) to the instrument panel duct (3). 7. Install the two screws (1) that secure the center distribution duct to the instrument panel support. Tighten the screws to 2 Nm (17 in. lbs.). 8. Install the demister ducts (2 and 6) See: Instrument Panel Demister Duct - Installation. 9. Install the two screws (3) that secure the instrument panel wire harness (4) to the instrument panel support (5). Tighten the screws to 2 Nm (17 in. lbs.). 10. Install the defroster duct (1) See: Defroster Duct - Installation. 11. Install the instrument panel top cover. 12. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. Instrument Panel Demister Duct - Removal REMOVAL NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage. DRIVER SIDE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7063 1. Remove the instrument panel and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 2. Remove the instrument panel top cover. 3. Remove the defroster duct See: Defroster Duct Removal. 4. Remove the two screws (1) that secure the driver side demister duct (2) to the back of the instrument panel. 5. Remove the two screws (4) that secure the instrument panel wire harness (3) to top of the instrument panel and carefully position the wire harness out of the way. 6. Remove the one screw (2) that secures the driver side demister duct (1) to the top of the instrument panel and remove the duct. Tilt and rotate the duct as necessary. PASSENGER SIDE INNER 1. Remove the instrument panel and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7064 and Repair/Instrument Panel - Removal. 2. Remove the defroster duct See: Defroster Duct - Removal. 3. Remove the two screws (2) that secure the passenger side inner demister duct (1) to the back of the instrument panel. 4. Disconnect the passenger side inner demister duct from the passenger side outer demister duct (3) and remove the inner duct. Tilt and rotate the duct as necessary. PASSENGER SIDE OUTER 1. Remove the instrument panel and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 2. Remove the instrument panel top cover. 3. Remove the defroster duct See: Defroster Duct Removal. 4. Remove the passenger side inner demister duct. 5. Remove the two screws (2) that secure the passenger side outer demister duct (1) to the top of the instrument panel. 6. Remove the passenger side outer demister duct from the instrument panel. Tilt and rotate the duct as necessary. Instrument Panel Demister Duct - Installation INSTALLATION DRIVER SIDE 1. Position the driver side demister duct (1) to the instrument panel. Tilt and rotate the duct as necessary. 2. Install the one screw (2) that secures the driver side demister duct to the top of the instrument panel. Tighten the screw to 2 Nm (17 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7065 3. Install the two screws (1) that secure the driver side demister duct (2) to the back of the instrument panel. Tighten the screws to 2 Nm (17 in. lbs.). 4. Reposition the instrument panel wire harness (3) to the instrument panel and install the two screws (4). Tighten the screws to 2 Nm (17 in. lbs.). 5. Install the defroster duct See: Defroster Duct - Installation. 6. Install the instrument panel top cover. 7. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. PASSENGER SIDE INNER 1. Position the passenger side inner demister duct (1) to the back of the instrument panel and connect it to the passenger side outer demister duct (3). Tilt and rotate the duct as necessary. 2. Install the two screws (2) that secure the passenger side inner demister duct to the instrument panel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the defroster duct See: Defroster Duct Installation. 4. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. PASSENGER SIDE OUTER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defroster Duct - Removal > Page 7066 1. Position the passenger side outer demister duct (1) to the instrument panel. Tilt and rotate the duct as necessary. 2. Install the two screws (2) that secure the passenger side outer demister duct to the top of the instrument panel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Install the passenger side inner demister duct. 4. Install the defroster duct See: Defroster Duct Installation. 5. Install the instrument panel top cover. 6. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Description and Operation > Front Air Outlet - Description Air Register: Description and Operation Front Air Outlet - Description DESCRIPTION NOTE: Dodge model shown. Chrysler model similar. There are two side window demister air outlets (1). One located on each end of the instrument panel top pad. The airflow from the side window demister air outlets is directed by fixed vanes in the demister outlet grilles and cannot be adjusted. The side window demister air outlets are serviceable from the instrument panel top pad. There are six instrument panel air outlets (2). One air outlet is located near each end of the instrument panel facing the rear of the vehicle, one outlet is on each side of the instrument panel center bezel and two outlets are located within the center bezel. Each of the instrument panel air outlets contain a grille with movable vanes that are used to direct or shut off the flow of the conditioned air leaving the instrument panel outlets. The driver side instrument panel air outlet is serviced with the instrument cluster bezel, the passenger side instrument panel air outlet is serviced with the passenger side trim panel and the two center air outlets are serviced with the center bezel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Description and Operation > Front Air Outlet - Description > Page 7071 Air Register: Description and Operation Rear Air Outlet - Description DESCRIPTION There are four rear ceiling air outlets (1) located in the headliner (2). One air outlet is located at each outboard side of the intermediate seat position facing the center of the vehicle, and one located in front of each rear seat position facing the rear of the vehicle. Each of the rear ceiling air outlets contain a grille with movable vanes (3) that are used to direct or shut off the flow of the conditioned air leaving the rear ceiling air outlets. The rear ceiling air outlets and grilles can each be serviced separately. There is one rear floor air outlet (1) located behind the right rear door area in the right quarter interior trim panel (2). The airflow from the rear floor air outlet is directed by fixed vanes in the right quarter interior trim panel and cannot be adjusted. The rear floor air outlet is not serviceable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal Air Register: Service and Repair Defroster Grille - Removal REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service Precautions 2. Using a trim stick C-4755 or equivalent, remove the drivers side A-pillar trim. 3. Open the trim covers in the passenger side A-pillar grab handle and remove the bolts. 4. Remove the right A-pillar trim panel. 5. Using a trim stick C-4755 or equivalent, remove the instrument panel defroster grille. 6. Disconnect the sensor electrical connector (3). 7. Disconnect the sun sensor (1) electrical connector, remove the metal clip, and unsnap the clips on sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal > Page 7074 Air Register: Service and Repair Defroster Grille - Installation INSTALLATION 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service Precautions 2. Install the sun sensor (1) and connect the sensor electrical connector, snap the sensor into defroster grille, and slide the metal clip on the bottom of the sensor. 3. Position the defroster grille (2) into place and connect the electrical connector (3). 4. Position the drivers side A-pillar trim into place and seat the retaining clips fully. 5. Position the passenger side A-pillar trim panel into place and seat fully. 6. Install the bolts and tighten to 6 Nm (55 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal > Page 7075 Air Register: Service and Repair Air Outlet - Removal Front REMOVAL NOTE: The instrument panel demister outlets are retained into the instrument panel top pad by a light snap fit. 1. Using Trim Stick C-4755 or equivalent, gently pry the instrument panel demister outlet(s) (1) out of the instrument panel top pad (2) as required. Rear Ceiling Air Outlet REAR CEILING AIR OUTLET 1. Using Trim Stick C-4755 or equivalent (1), gently pry between both bottom ends of the rear ceiling air outlet bezel (2) and the headliner (3) to release the snap clip retainers that secure the air outlet bezel to the headliner. 2. Remove the rear ceiling air outlet(s) from the headliner. Rear Ceiling Air Outlet Grille REAR CEILING AIR OUTLET GRILLE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal > Page 7076 1. Using a pick or another suitable tool (1), gently pry between the right end of the rear ceiling air outlet bezel (2) and the air outlet grille (3) to release the snap clip retainer that secures the grille to the pivot on the right side of the bezel. 2. Remove the rear ceiling air outlet grille (1) from the pivot on the left side of the air outlet bezel (2) by moving the grille out and to the right of the bezel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal > Page 7077 Air Register: Service and Repair Air Outlet - Installation Front INSTALLATION 1. Position the instrument panel demister outlet(s) (1) onto the instrument panel top pad (2). 2. Gently push the demister outlet(s) into the top pad until it snaps into place. Rear Ceiling Air Outlet REAR CEILING AIR OUTLET 1. Position the rear ceiling air outlet(s) (1) into the headliner (2). 2. Gently push the air outlet bezel (3) into the headliner until the snap clips in the headliner duct fully engage the slots in the bezel. Rear Ceiling Air Outlet Grille REAR CEILING AIR OUTLET GRILLE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Defroster Grille - Removal > Page 7078 1. Install the rear ceiling air outlet grille (1) onto the pivot shaft (2) on the left side of the air outlet bezel (3). 2. Gently push the air outlet grille (1) onto the pivot shaft (2) on the right side of the air outlet bezel (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Ambient Air Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Ambient Air Temperature Sensor > Page 7083 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7084 Ambient Temperature Sensor / Switch HVAC: Diagrams Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-AMBIENT AIR TEMPERATURE - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Front Ambient Temperature Sensor - Description Ambient Temperature Sensor / Switch HVAC: Description and Operation Front Ambient Temperature Sensor - Description DESCRIPTION The ambient air temperature sensor is a variable resistor that monitors the air temperature outside of the vehicle. The ambient air temperature sensor is mounted onto the inside of the front bumper beam and its data is used by the heating-A/C system to maintain optimum cabin temperature levels. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Front Ambient Temperature Sensor - Description > Page 7087 Ambient Temperature Sensor / Switch HVAC: Description and Operation Front Ambient Temperature Sensor - Operation OPERATION The ambient air temperature sensor is a variable resistor that operates on a ground circuit and a 5-volt reference signal circuit sent by the front control module (FCM) through a two-wire lead and connector of the vehicle wire harness. The ambient air temperature sensor changes its internal resistance in response to changes in the outside air temperature, which either increases or decreases the reference signal voltage read by the FCM. The FCM converts and broadcasts the sensor data over the controller area network (CAN) B bus, where it is read by the A/C-heater control and other various vehicle control modules. The ambient air temperature sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The ambient air temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged See: Instrument Panel, Gauges and Warning Indicators/Outside Temperature Display/Outside Temperature Display Sensor/Service and Repair/Ambient Temperature Sensor - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Auxiliary Water Pump > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Auxiliary Water Pump > Component Information > Locations > Page 7091 Auxiliary Water Pump: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 4 WAY PUMP-ELECTRIC COOLANT-HVAC (HEV) - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Auxiliary Water Pump > Component Information > Description and Operation > Auxiliary HVAC Heater Pump - Description Auxiliary Water Pump: Description and Operation Auxiliary HVAC Heater Pump - Description DESCRIPTION An auxiliary HVAC heater pump (1) is used to provide coolant flow through the front and rear heater cores on the Hybrid Electric Vehicle (HEV) models when operating the vehicle during both gasoline and electric motor operating modes. The auxiliary HVAC heater pump is mounted to the right side frame rail (4) in the engine compartment by a bracket (5) and contains an electric motor that drives a vane-type pump using a magnetic clutch. The pump housing has and electrical connector (6) for the motor and two connections for the heater hoses (2). The heater hoses are secured to the front of the pump housing by spring-type hose clamps (3). The auxiliary HVAC heater pump is of the identical design as the electric coolant pump for the Traction Power Inverter Module (TPIM), but is NOT interchangeable with the TPIM coolant pump due to different pump software. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Auxiliary Water Pump > Component Information > Description and Operation > Auxiliary HVAC Heater Pump - Description > Page 7094 Auxiliary Water Pump: Description and Operation Auxiliary HVAC Heater Pump - Operation OPERATION The auxiliary HVAC heater pump for the Hybrid Electric Vehicle (HEV) provides engine coolant flow through the front and rear heater cores during gasoline and electric motor operating modes. The auxiliary HVAC heater pump is controlled by the A/C-heater control and has a variable flow rate of approximately 8 - 19 liters (2 - 5 gallons) per minute. When the gasoline engine is operating below 1000 rpm, the auxiliary HVAC heater pump boosts engine coolant flow through the heater cores at the rate of 8 liters (2 gallons) per minute. When in electric operating mode, the A/C-heater control determines coolant flow rate based on infrared sensor data and customer temperature settings. The auxiliary HVAC heater pump is connected to the Powertrain control Module (PCM) via a Local Interconnect Network (LIN) bus. The A/C-heater control sends a flow rate command message to the Front Control Module (FCM) over the Controller Area Network (CAN) B bus. The FCM then converts and broadcasts the message over the CAN C bus to the PCM. The PCM converts the gallons per minute command from the A/C-heater control to a pump target RPM. If the A/C-heater control sends a non-zero flow rate command to the PCM and the PCM responds with a zero flow rate actual message, a Diagnostic Trouble Code (DTC) will set. The auxiliary HVAC heater pump can be actuated and diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. NOTE: The auxiliary HVAC heater pump is of the identical design as the electric coolant pump for the Traction Power Inverter Module (TPIM), but is NOT interchangeable with the TPIM coolant pump due to different pump software. The auxiliary HVAC heater pump cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Auxiliary Water Pump > Component Information > Service and Repair > Auxiliary HVAC Heater Pump - Removal Auxiliary Water Pump: Service and Repair Auxiliary HVAC Heater Pump - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions 1. Disconnect the high voltage battery system using the service disconnect at the battery pack See: Starting and Charging/Battery/Testing and Inspection. 2. Disconnect the 12 volt battery system. 3. Drain the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 4. Raise and support the vehicle. 5. Remove the right front wheelhouse splash shield (1) to gain access to the auxiliary HVAC heater pump (2) located on the right frame rail See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation. 6. If equipped, remove the splash shield from the auxiliary HVAC heater pump. 7. Disconnect the electrical connector (3). NOTE: If the heater hoses are cut during removal from the auxiliary HVAC heater pump, they must be replaced. 8. Loosen the hose clamps (3) and disconnect the heater hoses (2) from the auxiliary HVAC heater pump (1). 9. Remove the two bolts (5) that secure the auxiliary HVAC heater pump to the right frame rail (4) and remove the pump from the vehicle. 10. If required, remove the retaining bracket (6) from the auxiliary HVAC heater pump. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Auxiliary Water Pump > Component Information > Service and Repair > Auxiliary HVAC Heater Pump - Removal > Page 7097 Auxiliary Water Pump: Service and Repair Auxiliary HVAC Heater Pump - Installation INSTALLATION 1. If required, install the retaining bracket (6) onto the auxiliary HVAC heater pump (1). Make sure the bracket is properly orientated the pump. Tighten the bolt securely. 2. Position the auxiliary HVAC heater pump to the right frame rail (4) and install the two retaining bolts (5). Tighten the bolts to 8.5 Nm (75 in. lbs.). 3. Connect the heater hoses (2) to the auxiliary HVAC heater pump. Make sure the hose clamps (3) are securely engaged. 4. Connect the electrical connector (3) to the auxiliary HVAC heater pump (2). 5. If equipped, install the auxiliary HVAC heater pump splash shield. 6. Install the right front wheelhouse splash shield (1) See: Body and Frame/Fender/Front Fender/Front Fender Liner/Description and Operation. 7. Lower the vehicle. 8. Reconnect the 12 volt battery system. 9. Reconnect the high voltage battery system See: Starting and Charging/Battery/Service and Repair/Procedures. 10. Refill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Front Blower Motor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Front Blower Motor > Page 7102 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Blower Motor: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7105 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7106 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7107 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7108 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7109 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7110 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7111 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7112 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7113 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7114 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7115 Blower Motor: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7116 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7117 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7118 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7119 Blower Motor: Connector Views Front Blower Motor (HVAC) 2 Way Connector - (HVAC) 2 WAY MOTOR-BLOWER-FRONT - (HVAC) 2 WAY Rear Blower Motor (HVAC) 2 Way Connector - (HVAC) 2 WAY MOTOR-BLOWER-REAR - (HVAC) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7120 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Description - Front Blower Motor: Description and Operation Description - Front DESCRIPTION The blower motor (1) is a 12-volt, direct current (DC) motor with a squirrel cage-type blower wheel (2) that is secured to the blower motor shaft (3). The blower motor and wheel are located near the passenger side end of the HVAC housing in the passenger compartment below the instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Description - Front > Page 7123 Blower Motor: Description and Operation Description - Rear DESCRIPTION The rear blower motor (1) and blower wheel (2) is located in the rear heater-A/C housing behind the right interior quarter panel trim and is connected to rear heater-A/C wire harness by a integral wire harness connector (3). The rear blower motor controls the velocity of air flowing through the rear heater-A/C housing by spinning the wide squirrel cage-type blower wheel at the selected speed. Rear blower motor speed is controlled by regulating the ground path through the rear blower motor switch and the rear blower motor resistor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Description - Front > Page 7124 Blower Motor: Description and Operation Operation - Front OPERATION The blower motor is used to control the velocity of air moving through the HVAC housing by spinning the blower wheel within the housing at the selected speed whenever the ignition switch is in RUN and the blower control switch is in any position except OFF. Blower motor speed is controlled by regulating the path to ground through the blower motor control switch and the blower motor resistor. The blower motor receives battery current whenever the blower motor relay is energized. The blower motor relay output circuit is protected by a fuse in the integrated power module (IPM) located in the engine compartment. The blower motor and blower wheel are factory balanced and cannot be adjusted or repaired and must be replaced as an assembly if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Description - Front > Page 7125 Blower Motor: Description and Operation Operation - Rear OPERATION The rear blower motor is used to control the velocity of air moving through the rear heater-A/C housing by spinning the blower wheel within the housing at the selected speed. The rear blower motor will only operate when the ignition switch is in RUN and the front A/C-heater control is set to either front control of rear heating-A/C system or to the rear control of the rear heating-A/C system. The rear blower motor receives a battery feed through the rear blower motor relay located in the power distribution center (PDC) whenever the ignition switch is in RUN See: Testing and Inspection. The rear blower motor and blower wheel are factory balanced and cannot be adjusted or repaired and must be replaced as an assembly if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Description and Operation > Page 7126 Blower Motor: Testing and Inspection BLOWER MOTOR WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: See Wiring Information for circuit descriptions and diagrams, Possible causes of an inoperative front or rear blower motor include: - Open fuse (the rear blower motor fuse is located in the relay and fuse block located on the back of the junction block) - Inoperative blower motor resistor block or power module (depending on application) - Inoperative blower motor relay (Voltage Reduction Relay or VRR) (front only) - Inoperative blower motor - Inoperative blower motor switch - Inoperative heater-A/C mode control switch (front only) - Blower motor circuit wiring or wire harness connectors Possible causes of the front or rear blower motor not operating in all speeds include: - Inoperative blower motor resistor block or power module (depending on application) - Inoperative blower motor switch - Inoperative blower motor circuit wiring or wire harness connectors VIBRATION Possible causes of front or rear blower motor vibration include: - Improper blower motor mounting - Blower wheel out of balance or deformed - Foreign material in blower wheel causing out of balance condition - Worn blower motor NOISE To determine if the front or rear blower motor is the source of the noise, simply switch the front or rear blower motor from Off to On. To verify that the blower motor is the source of the noise, unplug the blower motor wire harness connector and operate the heater-A/C system. If the noise goes away, possible causes include: - Improper blower motor mounting - Foreign material in blower wheel - Foreign material in HVAC housing - Worn blower motor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal - Front Blower Motor: Service and Repair Removal - Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the right front door scuff plate See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Description and Operation. 3. Remove the right cowl side trim panel. 4. Disconnect the wire harness connector (1) from the blower motor (2). 5. Remove the three screws (3) that secure the blower motor and blower wheel assembly to the HVAC housing (4). 6. Remove the blower motor and blower wheel assembly from the HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal - Front > Page 7129 Blower Motor: Service and Repair Removal - Rear REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the rear heater-A/C housing (4) See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal. 3. Disconnect the rear heater-A/C wire harness connector (1) from the rear blower motor (2). 4. Remove the three screws (3) that secure the rear blower motor to the rear housing and remove the blower motor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal - Front > Page 7130 Blower Motor: Service and Repair Installation - Front INSTALLATION 1. Position the blower motor and blower wheel assembly (2) into the HVAC housing (4). 2. Install the three screws (3) that secure the blower motor and blower wheel assembly to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Connect the wire harness connector (1) to the blower motor. 4. Install the right cowl side trim panel. 5. Install the right front door scuff plate See: Body and Frame/Interior Moulding / Trim/Scuff Plate/Description and Operation. 6. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair > Removal - Front > Page 7131 Blower Motor: Service and Repair Installation - Rear INSTALLATION 1. Position the rear blower motor (2) into the rear heater-A/C housing (4). 2. Install the three screws (3) that secure the rear blower motor to the rear housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Connect the rear heater-A/C wire harness connector (1) to the rear blower motor. 4. Install the rear heater-A/C housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Installation. 5. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay Blower Motor Relay: Locations Front Blower Motor Relay Front Blower Motor Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 7136 Blower Motor Relay: Locations Rear Blower Motor Relay Rear Blower Motor Relay is located in the Junction Block (JB). Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Relay-Blower Motor-Front Blower Motor Relay: Diagrams Relay-Blower Motor-Front Connector (IN PDC) RELAY-BLOWER MOTOR-FRONT (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams > Relay-Blower Motor-Front > Page 7139 Blower Motor Relay: Diagrams Relay-Blower Motor-Rear Connector (IN JB) RELAY-BLOWER MOTOR-REAR (IN JB) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay - Description Blower Motor Relay: Description and Operation Front Blower Motor Relay - Description DESCRIPTION The blower motor relay (1) for the standard front heating-A/C system is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal function and patterns (2). The front blower motor relay is a electromechanical device that switches battery current from a fuse in the power distribution center (PDC) directly to the front blower motor when equipped with the manual temperature control (MTC) system, or the blower motor power module when equipped with the automatic temperature control (ATC) system. The front blower motor relay is energized when the relay coil is provided a ground circuit through the integrated power module. The front blower motor relay is located in the power distribution center (PDC) in the engine compartment. Refer to the PDC label for front blower motor relay identification and location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay - Description > Page 7142 Blower Motor Relay: Description and Operation Front Blower Motor Relay - Operation OPERATION The ISO-standard front blower motor relay is an electromechanical switch that uses a low current input from the battery to control the high current output to the front blower motor. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the front blower motor. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The front blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the power distribution center (PDC). The inputs and outputs of the front blower motor relay include: - The common feed terminal (30) receives battery current through a fuse in the PDC at all times. - The coil ground terminal (85) receives a ground circuit through the integrated power module. - The coil battery terminal (86) receives battery current through a fuse in the PDC at all times. - The normally open terminal (87) provides battery current output to the front blower motor when equipped with the manual temperature control (MTC) system, or the blower motor power module when equipped with the automatic temperature control (ATC) system only when the front blower motor relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the front blower motor relay coil is de-energized. The front blower motor relay cannot be adjusted or repaired and must be replaced if inoperative or damaged. See Wiring Information for diagnosis and testing of the blower motor relay and for complete HVAC wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay - Description > Page 7143 Blower Motor Relay: Description and Operation Rear Blower Motor Relay - Description DESCRIPTION The blower motor relay (1) for the rear heating-A/C system is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal function and patterns (2). The rear blower motor relay is a electromechanical device that switches battery current from a fuse in the junction block directly to the rear blower motor. The rear blower motor relay is energized when the relay coil is provided a voltage signal by the ignition switch. The rear blower motor relay is located in the junction block (JB) in the passenger compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay - Description > Page 7144 Blower Motor Relay: Description and Operation Rear Blower Motor Relay - Operation OPERATION The ISO-standard rear blower motor relay is an electromechanical switch that uses a low current input from the ignition switch to control the high current output to the rear blower motor. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the rear blower motor. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the junction block (JB). The inputs and outputs of the rear blower motor relay include: - The common feed terminal (30) receives fused battery current at all times. - The coil ground terminal (85) is connected to a ground at all times. - The coil battery terminal (86) receives battery current from a fuse in the junction block (JB) through an ignition switch output (run) circuit only when the ignition switch is in RUN. - The normally open terminal (87) provides battery current output to the rear blower motor through the rear blower motor relay output circuit only when the rear blower motor relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the rear blower motor relay coil is de-energized. The rear blower motor relay cannot be adjusted or repaired and must be replaced if inoperative or damaged. See Wiring Information for diagnosis and testing of the rear blower motor relay and for complete HVAC wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Service and Repair > Front Blower Motor Relay - Removal Blower Motor Relay: Service and Repair Front Blower Motor Relay - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Locate the power distribution center (PDC) (1). 3. Open the PDC cover (2). NOTE: Refer to the fuse and relay layout map on the inner surface of the PDC cover for rear blower motor relay identification and location. 4. Remove the rear blower motor relay (3) from the PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Service and Repair > Front Blower Motor Relay - Removal > Page 7147 Blower Motor Relay: Service and Repair Front Blower Motor Relay - Installation INSTALLATION NOTE: Refer to the fuse and relay layout map on the inner surface of the PDC cover for rear blower motor relay identification and location. 1. Position the rear blower motor relay (3) into the proper receptacle of the PDC (1). 2. Align the rear blower motor relay terminals with the terminal cavities in the PDC receptacle and push down firmly on the relay until the terminals are fully seated. 3. Close the PDC cover (2). 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Service and Repair > Front Blower Motor Relay - Removal > Page 7148 Blower Motor Relay: Service and Repair Rear Blower Motor Relay - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Locate the junction block (JB) (1) on the left side of the passenger compartment behind the cowl side trim panel. 3. Remove the rear blower motor relay (2) from the JB. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Service and Repair > Front Blower Motor Relay - Removal > Page 7149 Blower Motor Relay: Service and Repair Rear Blower Motor Relay - Installation INSTALLATION 1. Position the rear blower motor relay (2) into the proper receptacle of the junction block (JB) (1). 2. Align the rear blower motor relay terminals with the terminal cavities in the JB receptacle and push down firmly on the relay until the terminals are fully seated. 3. Reinstall the cowl side trim panel. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Front Blower Motor Resistor (MTC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations > Front Blower Motor Resistor (MTC) > Page 7154 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Front Blower Motor Resistor (MTC) 5 Way Blower Motor Resistor: Diagrams Front Blower Motor Resistor (MTC) 5 Way Connector (MTC) - 5 WAY RESISTOR-BLOWER MOTOR-FRONT (MTC) - 5 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Front Blower Motor Resistor (MTC) 5 Way > Page 7157 Blower Motor Resistor: Diagrams Rear Blower Motor Resistor (Rear HVAC) 3 Way Connector - (REAR HVAC) 3 WAY RESISTOR-BLOWER MOTOR-REAR - (REAR HVAC) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Description - Front Blower Motor Resistor: Description and Operation Description - Front DESCRIPTION A blower motor resistor is used on vehicles equipped with the manual temperature control (MTC) heating-A/C system. Vehicles equipped with the automatic temperature control (ATC) heating-A/C system use a blower motor power module, instead of the blower motor resistor See: Control Module HVAC/Description and Operation/Front Blower Motor Power Module - Description. The front blower motor resistor is mounted to the rear of the HVAC housing, directly behind the glove box. The blower motor resistor consists of a molded plastic mounting plate (1) with an integral wire connector receptacle (2). Concealed behind the mounting plate are coiled resistor wires contained within a ceramic heat sink (3). The front blower motor resistor is accessed for service from beneath the right side of the instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Description - Front > Page 7160 Blower Motor Resistor: Description and Operation Description - Rear DESCRIPTION A rear blower motor resistor is used on this model when it is equipped with the rear heater-A/C system. The rear blower motor resistor is mounted to the rear heater-A/C housing, directly below the rear blower motor. The rear blower motor resistor consists of a molded plastic mounting plate (1) with an integral wire connector receptacle (2). Concealed behind the mounting plate are coiled resistor wires contained within a ceramic heat sink (3). The rear blower motor resistor is accessed for service by removing the rear quarter interior trim panel from the right side of the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Description - Front > Page 7161 Blower Motor Resistor: Description and Operation Operation - Front OPERATION The blower motor resistor is connected to the vehicle electrical system through a dedicated wire lead and connector of the HVAC wire harness. The blower motor resistor has multiple resistor wires, each of which will reduce the current flow through the blower motor to change the blower motor speed. The blower motor switch in the MTC heating-A/C system directs the ground path for the blower motor through the correct resistor wire to obtain the selected speed. With the blower motor control in the lowest speed position, the ground path for the blower motor is applied through all of the resistor wires. Each higher speed selected with the blower motor control applies the blower motor ground path through fewer of the resistor wires, increasing the blower motor speed. The blower motor resistor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description and Operation > Description - Front > Page 7162 Blower Motor Resistor: Description and Operation Operation - Rear OPERATION The blower motor resistor for the rear heating-A/C system is connected to the vehicle electrical system through a dedicated wire lead and connector of the rear heater-A/C wire harness. The rear blower motor resistor has multiple resistor wires, each of which will reduce the current flow through the blower motor to change the blower motor speed. The blower motor switch in the rear heater-A/C system directs the ground path for the rear blower motor through the correct resistor wire to obtain the selected speed. With the rear blower motor control in the lowest speed position, the ground path for the rear blower motor is applied through all of the resistor wires. Each higher speed selected with the rear blower motor control applies the blower motor ground path through fewer of the resistor wires, increasing the rear blower motor speed. The rear blower motor resistor cannot be adjusted or repaired and it must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Front Blower Motor Resistor Blower Motor Resistor: Testing and Inspection Front Blower Motor Resistor FRONT BLOWER MOTOR RESISTOR WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: See Wiring Information for circuit descriptions and diagrams. Wiring Information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector from the blower motor resistor . 3. Using an ohmmeter, check for continuity between all of the blower motor resistor terminals. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor switch and the blower motor resistor or blower motor as required. If not OK, replace the inoperative blower motor resistor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Testing and Inspection > Front Blower Motor Resistor > Page 7165 Blower Motor Resistor: Testing and Inspection Rear Blower Motor Resistor REAR BLOWER MOTOR RESISTOR NOTE: See Wiring Information for circuit descriptions and diagrams. Wiring Information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector from the blower motor resistor . 3. Using an ohmmeter, check for continuity between all of the blower motor resistor terminals. In each case there should be continuity. If OK, repair the wire harness circuits between the blower motor switch and the blower motor resistor or the blower motor as required. If not OK, replace the inoperative blower motor resistor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Removal - Front Blower Motor Resistor: Service and Repair Removal - Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor resistor, wait five minutes to allow the blower motor resistors to cool before performing diagnosis or service. Failure to take this precaution may result in possible injury. CAUTION: Do not operate the blower motor with the blower motor resistor removed from the circuit. Failure to take this precaution can result in vehicle damage. 1. Disconnect and isolate the negative battery cable. 2. If equipped with a trim cover (2) remove the two screws (1) that secure the trim cover over the blower motor resistor (3) located below the right side of the instrument panel and remove the cover. 3. Disconnect the wire harness connector (1) from the blower motor resistor (2). 4. Remove the two screws (3) that secure the blower motor resistor to the front HVAC housing. 5. Remove the blower motor resistor from the front HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Removal - Front > Page 7168 Blower Motor Resistor: Service and Repair Removal - Rear REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the right rear quarter interior trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the rear heater-A/C wire harness connector (4) from the rear blower motor resistor (1). 4. Remove the screw (3) that secures the rear blower motor resistor to the rear heater-A/C housing (2). 5. Disengage the rear blower motor resistor from the rear heater-A/C housing and remove the resistor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Removal - Front > Page 7169 Blower Motor Resistor: Service and Repair Installation - Front INSTALLATION 1. Position the blower motor resistor (2) into the front HVAC housing (4). 2. Install the two screws (3) that secure the blower motor resistor to the front HVAC housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the wire harness connector (1) to the blower motor resistor. 4. If equipped with a trim cover (2), install the trim cover over the blower motor resistor (3) and install the two retaining screws (1). Tighten the screws to 2 Nm (17 in. lbs.). 5. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Service and Repair > Removal - Front > Page 7170 Blower Motor Resistor: Service and Repair Installation - Rear INSTALLATION 1. Position the rear blower motor resistor (1) into the rear heater-A/C housing (2). Make sure the resistor is fully engage by the retaining tab on the housing 2. Install the screw (3) that secures the rear blower motor resistor to the rear heater-A/C housing. Tighten the screw to 2 Nm (17 in. lbs.). 3. Connect the rear heater-A/CC wire harness connector (3) to the rear blower motor resistor. 4. Install the right rear quarter interior trim panel See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 5. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications CLUTCH GAP The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 7175 Compressor Clutch: Diagrams Connector - (ENGINE) 2 WAY CLUTCH-A/C COMPRESSOR - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > A/C Compressor Clutch - Description Compressor Clutch: Description and Operation A/C Compressor Clutch - Description A/C CLUTCH - GAS MODELS NOTE: Typical A/C clutch assembly shown. The clutch assembly for models equipped with the Denso 10SR17 and 10SRE20 A/C compressors consists of a stationary electromagnetic A/C clutch field coil (4), pulley bearing and pulley assembly (3), clutch plate (2) and shims (7). These components provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. The A/C clutch field coil and the pulley bearing and pulley assembly are both retained on the nose of the A/C compressor with snap rings (5 and 6). The clutch plate is splined to the compressor shaft and secured with a bolt (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > A/C Compressor Clutch - Description > Page 7178 Compressor Clutch: Description and Operation A/C Compressor Clutch - Operation A/C CLUTCH - GAS MODELS The clutch components for the Denso 10SR17 and 10SRE20 A/C compressors provide the means to engage and disengage the A/C compressor from the engine accessory drive belt. When the electromagnetic A/C clutch field coil is energized, it magnetically draws the clutch plate into contact with the clutch pulley and drives the compressor shaft. When the coil is not energized, the pulley freewheels on the clutch hub bearing, which is part of the pulley assembly. The A/C compressor clutch engagement is controlled by the following components: - A/C clutch relay in the Power Distribution Center (PDC) - A/C-heater control in the passenger compartment - A/C pressure transducer on the A/C discharge line - Powertrain Control Module (PCM) in the engine compartment The A/C compressor clutch components cannot be repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Description and Operation > Page 7179 Compressor Clutch: Testing and Inspection A/C CLUTCH PLATE INSPECTION NOTE: The A/C clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley and bearing assembly, or coil replacement. When equipped with the Denso 10SR17 and 10SRE20 A/C compressor, examine the friction surfaces of the pulley and the clutch plate (2) for wear. The pulley and clutch plate should be replaced if excessive wear or scoring is found. If the friction surfaces are oily, inspect the shaft and nose area of the A/C compressor (1) for refrigerant oil. If refrigerant oil is found, the compressor shaft seal is leaking and the A/C compressor must be replaced. Check the pulley bearing for roughness or excessive leakage of grease. The pulley and clutch plate should be replaced if bearing roughness or excessive leakage is found. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch - Removal Compressor Clutch: Service and Repair A/C Compressor Clutch - Removal A/C CLUTCH - GAS MODELS NOTE: The compressor clutch assembly can be serviced with the refrigerant system fully-charged. NOTE: Typical A/C compressor and clutch assembly shown in illustrations. 1. Disconnect and isolate the negative battery cable. 2. Remove the air intake hose from the air filter housing and the resonator See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. 3. Partially drain the engine cooling system and disconnect the upper radiator hose from the radiator and position the hose out of the way See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 4. Remove the radiator fan and shroud See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan. 5. Remove the accessory drive belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Removal. 6. Disconnect the engine wire harness from the compressor clutch coil connector (1) located on the top of the A/C compressor (5). 7. Carefully remove the compressor clutch coil connector and wire lead from the connector bracket (2). 8. Remove the compressor shaft bolt (3). A band-type oil filter wrench or a strap wrench may be used to hold the clutch plate (4) from rotating during bolt removal. CAUTION: Do not pry between the clutch plate and the pulley and bearing assembly to remove the clutch plate from the compressor shaft as Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch - Removal > Page 7182 this may damage the clutch plate. NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate, as they may be reused during the clutch plate installation process. 9. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1) and remove the clutch plate and shim(s) (3). 10. Using A/C Snap Ring Pliers 9764 (1) or equivalent, remove the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor and remove the pulley and bearing assembly. 11. Using A/C Snap Ring Pliers 9764 (1) or equivalent, remove the snap ring (4) that secures the compressor clutch coil (2) to the front of the A/C compressor (3) and remove the coil. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch - Removal > Page 7183 Compressor Clutch: Service and Repair A/C Compressor Clutch - Installation A/C CLUTCH - GAS MODELS NOTE: Typical A/C compressor and clutch assembly shown in illustrations. 1. Align the dowel pin on the back of the compressor clutch coil (2) with the hole in the front of the A/C compressor (3) and position the coil onto the compressor. Be certain that the compressor clutch coil wire lead is properly routed so that it is not pinched between the A/C compressor and the coil. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the compressor clutch coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the coil dowel pin location on the A/C compressor. 2. Using A/C Snap Ring Pliers 9764 (1) or equivalent, install the snap ring (4) that secures the compressor clutch coil to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly. CAUTION: Be certain to position the A/C clutch coil wire lead so that it is not damaged during A/C compressor pulley and bearing installation. CAUTION: When installing the pulley and bearing assembly, DO NOT mar the friction surfaces of the pulley or premature failure of the A/C clutch will result. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch - Removal > Page 7184 3. Install the pulley and bearing assembly (1) onto the front of the A/C compressor. If necessary, tap the pulley gently with a block of wood (2) placed on the pulley friction surface. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward. 4. Using A/C Snap Ring Pliers 9764 (1) or equivalent, install the snap ring (2) that secures the pulley and bearing assembly (3) to the front of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove. 5. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim(s) (3) onto the compressor shaft (1). If a new clutch plate and pulley and bearing assembly are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick onto the compressor shaft. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Service and Repair > A/C Compressor Clutch - Removal > Page 7185 6. Install the clutch plate (4) onto the front of the A/C compressor (5). 7. Install the compressor shaft bolt (3). Tighten the bolt to 19 Nm (168 in. lbs.). NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is correct. Spin the pulley before performing a final check of the air gap. NOTE: On models with the clutch plate recessed into the pulley, use a 90° wire gap gauge to measure the clutch air gap. On other models, use a blade type feeler gauge to measure the air gap. 8. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly. The air gap should be between 0.35 - 0.60 mm (0.014 - 0.024 in.). If the air gap is not between specifications, add or subtract shims as needed until the correct air gap is obtained. CAUTION: Be certain that the A/C clutch coil wire harness is properly routed so that it is not pinched between the A/C compressor and the coil connector bracket. 9. Carefully route the compressor clutch coil wire lead behind the connector bracket (2). 10. Install the compressor clutch coil connector (1) onto the connector bracket. 11. Connect the engine wire harness to the compressor clutch coil connector. 12. Install the accessory drive belt See: Engine, Cooling and Exhaust/Engine/Drive Belts, Mounts, Brackets and Accessories/Drive Belt/Service and Repair/Removal and Replacement/Serpentine Accessory Drive Belt - Installation. 13. Install the radiator fan and shroud See: Engine, Cooling and Exhaust/Cooling System/Radiator Cooling Fan. 14. Connect the upper radiator hose to the radiator and securely install the hose clamp. 15. Install the air intake hose See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation. 16. Refill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 17. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Testing and Inspection Compressor Clutch Coil: Testing and Inspection A/C COMPRESSOR CLUTCH COIL The clutch coil electrical circuit for the A/C compressor on gasoline only models are controlled by the powertrain control module (PCM) through the A/C compressor clutch relay, which is located in the power distribution center (PDC) in the engine compartment. Begin testing of a suspected compressor clutch coil problem by performing the preliminary checks. PRELIMINARY CHECKS 1. If the compressor clutch will not engage, perform the A/C System Performance Test, which is found within the HVAC System Test See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. If no diagnostic trouble codes (DTCs) are found in the A/C-heater control or the powertrain control module (PCM), go to 2. If any DTCs are found, repair as required. 2. If the compressor clutch still will not engage, verify the refrigerant charge level See: Testing and Inspection/Component Tests and General Diagnostics. If the refrigerant charge level is OK, go to TESTS. If the refrigerant charge level is not OK, adjust the refrigerant charge as required. TESTS 1. Verify the battery state of charge See: Starting and Charging/Battery/Testing and Inspection/Battery. 2. Connect an ammeter (0 to 10 ampere scale selected) in series with the clutch field coil feed terminal using Back Probe Tool 6801. Connect a voltmeter (0 to 20 volt scale selected) to measure voltage across the battery and the clutch coil. 3. With the A/C-heater control in the A/C mode and the blower at low speed, start the engine and allow it to run at a normal idle speed. 4. The compressor clutch should engage immediately and the clutch coil supply voltage should be within two volts of the battery voltage. If the coil supply voltage is OK, go to 5. If the coil supply voltage is not within two volts of battery voltage, test the clutch coil feed circuit for excessive voltage drop and repair as necessary. 5. The A/C clutch coil current draw should be 2.2 - 4.0 amps @ 12 volt ± 0.5 volt. Specifications apply for a work area temperature of 21° C (70° F). If voltage is more than 12.5 volts, add electrical loads by turning on electrical accessories until voltage reads below 12.5 volts. a. If the compressor clutch coil current reading is zero, the coil is open and must be replaced. b. If the compressor clutch coil current reading is above specifications, the coil is shorted and must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations A/C Clutch Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Description and Operation > A/C Clutch Relay - Description Compressor Clutch Relay: Description and Operation A/C Clutch Relay - Description DESCRIPTION The A/C clutch relay (1) is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The A/C clutch relay is located in the power distribution center (PDC) in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Description and Operation > A/C Clutch Relay - Description > Page 7194 Compressor Clutch Relay: Description and Operation A/C Clutch Relay - Operation OPERATION The ISO-standard A/C clutch micro-relay is an electromechanical switch that uses a low current input controlled by the powertrain control module (PCM) to control the high current output to the A/C clutch field coil. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the A/C clutch field coil. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The A/C clutch relay terminals are connected to the vehicle electrical system through a receptacle in the power distribution center (PDC). The inputs and outputs of the A/C clutch relay include: - The common feed terminal (30) receives fused battery current at all times. - The coil ground terminal (85) receives a ground input from the PCM through the A/C clutch relay control circuit only when the PCM electronically pulls the control circuit to ground. - The coil battery terminal (86) receives fused battery current through a ignition switch output (run-start) circuit only when the ignition switch is in the On or Start positions. - The normally open terminal (87) provides a battery current output to the A/C clutch coil through the A/C clutch relay output circuit only when the compressor clutch relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the A/C clutch relay coil is de-energized. The A/C clutch relay cannot be adjusted or repaired and must be replaced if inoperative or damaged. See Wiring Information for diagnosis and testing of the A/C clutch relay and for complete HVAC wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Service and Repair > A/C Clutch Relay - Removal Compressor Clutch Relay: Service and Repair A/C Clutch Relay - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Locate the power distribution center (PDC) (1). 3. Open the PDC cover (2). NOTE: Refer to the fuse and relay map on the inside of the PDC cover for A/C clutch relay location. 4. Remove the A/C clutch relay (3) from the PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Service and Repair > A/C Clutch Relay - Removal > Page 7197 Compressor Clutch Relay: Service and Repair A/C Clutch Relay - Installation INSTALLATION NOTE: Refer to the fuse and relay map on the inside of the PDC cover for A/C clutch relay location. 1. Position the A/C clutch relay (3) into the proper receptacle of the PDC (1). 2. Align the A/C clutch relay terminals with the terminal cavities in the PDC receptacle and push down firmly on the relay until the terminals are fully seated. 3. Close the PDC cover (2). 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > A/C Condenser - Description Condenser HVAC: Description and Operation A/C Condenser - Description DESCRIPTION The A/C condenser (2) is located in the front of the engine compartment inside of the condenser fan shroud (3). The A/C condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the A/C compressor to give up its heat to the air passing over the condenser fins, which causes the refrigerant to change to a liquid state. The A/C condenser is retained within the condenser fan shroud by two bolts (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Description and Operation > A/C Condenser - Description > Page 7202 Condenser HVAC: Description and Operation A/C Condenser - Operation OPERATION When air passes through the fins of the A/C condenser, the high-pressure refrigerant gas within the A/C condenser gives up its heat. The refrigerant then condenses as it leaves the A/C condenser and becomes a high-pressure liquid. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the A/C system. Therefore, it is important that there are no objects placed in front of the radiator grille openings at the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or A/C condenser service. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C condenser has no serviceable parts except for the O-ring seals and gaskets. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever a refrigerant line is disconnected from the A/C condenser. The A/C condenser cannot be repaired and must be replaced if leaking or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > A/C Condenser - Removal Condenser HVAC: Service and Repair A/C Condenser - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 4. Remove the push-pin retainers (1) and the upper condenser/radiator seal (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > A/C Condenser - Removal > Page 7205 5. Disconnect the wire harness connectors from the condenser cooling fan motor (9) and the A/C pressure transducer (10). 6. Remove the two wire harness retainers (2) from the condenser fan shroud (4) and position the wire harness out of the way. 7. Remove the nuts (1 and 8) that secure the A/C discharge line (5) and A/C liquid line (7) to the A/C condenser (6). 8. Disconnect the A/C discharge and liquid lines from the A/C condenser and remove and discard the O-ring seals and gaskets. 9. Remove the A/C discharge line from the retainer (3) located on the condenser fan shroud (4). 10. Install plugs in, or tape over the opened discharge and liquid line fitting and condenser ports. 11. Remove the three bolts (1) that secure the upper radiator support (2) to the upper front crossmember (5). 12. Remove the upper radiator support and position the radiator overflow hose (3) out of the way. 13. Remove the bolt that secures the condenser/cooling fan assembly (4) to the upper left fender rail. 14. Carefully push back the radiator (6) for clearance and remove the condenser/cooling fan assembly from the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > A/C Condenser - Removal > Page 7206 15. Place the condenser/cooling fan assembly on a workbench and remove the two screws (1) that secure the A/C condenser (2) to the condenser fan shroud (3). 16. Remove the A/C condenser from the condenser fan shroud. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > A/C Condenser - Removal > Page 7207 Condenser HVAC: Service and Repair A/C Condenser - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: Always use ND-11 Polyester (POE) oil from Mopar(R) in Hybrid Electric Vehicle (HEV) models. Never use Polyalkylene Glycol (PAG) oil in an HEV model. See Refrigerant Oil for more information. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: If only the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: Be certain that each of the radiator and condenser air seals are installed in their proper locations. These air seals are required for the A/C and engine cooling systems to perform as designed. 1. Position the A/C condenser (2) into the condenser fan shroud (3). 2. Install the two bolts (1) that secure the A/C condenser to the condenser fan shroud. Tighten the bolts to 5 Nm (45 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > A/C Condenser - Removal > Page 7208 3. Carefully push back the radiator (6) for clearance and install the condenser/cooling fan assembly (4). Insert the two lower condenser fan shroud mounting tabs into the holes in the lower front crossmember. 4. Install the bolt that secures the condenser/cooling fan assembly to the upper left fender rail. Tighten the bolt to 9.5 Nm (85 in. lbs.). 5. Position the radiator overflow hose (3) to it's installed location 6. Align the upper mounting tab of the condenser/cooling fan assembly to the hole in the upper radiator support (2) and install the upper radiator support. 7. Install the three bolts (1) that secure the upper radiator support to the upper front crossmember (5). Tighten the bolts to 23 Nm (17 ft. lbs.). 8. Remove the tape or plugs from the discharge and liquid line fittings and condenser ports. 9. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the discharge and liquid line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 10. Connect the A/C discharge line (5) and the A/C liquid line (7) to the A/C condenser (6). 11. Install the nuts (1 and 8) that secure the A/C discharge and liquid lines to the A/C condenser. Tighten the nuts to 22 Nm (16 ft. lbs.). 12. Install the A/C discharge line into the retainer (3) located on the condenser fan shroud. 13. Install the wire harness and the two wire harness retainers (2) to the condenser fan shroud (4). 14. Connect the wire harness connectors to the condenser cooling fan motor (9) and the A/C pressure transducer (10). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > A/C Condenser - Removal > Page 7209 15. Position the upper condenser/radiator seal (2) and install the push-pin retainers (1). WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 16. On HEV models, reconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 17. On gasoline only models, reconnect the negative battery cable. 18. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 19. If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 20. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Front A/C-Heater Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations > Front A/C-Heater Module > Page 7214 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Front A/C-Heater Module C1 (ATC) (Instrument Panel) 16 Way Control Assembly: Diagrams Front A/C-Heater Module C1 (ATC) (Instrument Panel) 16 Way Connector C1 (ATC) - (INSTRUMENT PANEL) 16 WAY MODULE-A/C-HEATER-FRONT (ATC) - (INSTRUMENT PANEL) 16 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Front A/C-Heater Module C1 (ATC) (Instrument Panel) 16 Way > Page 7217 Control Assembly: Diagrams Front A/C-Heater Module C1 (MTC) (Instrument Panel) 20 Way Connector C1 (MTC) - (INSTRUMENT PANEL) 20 WAY MODULE-A/C-HEATER-FRONT (MTC) - (INSTRUMENT PANEL) 20 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Front A/C-Heater Module C1 (ATC) (Instrument Panel) 16 Way > Page 7218 Control Assembly: Diagrams Front A/C-Heater Module C2 (ATC) (Instrument Panel) 12 Way Connector C2 (ATC) - (INSTRUMENT PANEL) 12 WAY MODULE-A/C-HEATER-FRONT (ATC) - (INSTRUMENT PANEL) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Front A/C-Heater Module C1 (ATC) (Instrument Panel) 16 Way > Page 7219 Control Assembly: Diagrams Front A/C-Heater Module C2 (MTC) (Instrument Panel) 8 Way Connector C2 (MTC) - (INSTRUMENT PANEL) 8 WAY MODULE-A/C-HEATER-FRONT (MTC) - (INSTRUMENT PANEL) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Front A/C-Heater Module C1 (ATC) (Instrument Panel) 16 Way > Page 7220 Control Assembly: Diagrams Front A/C-Heater Module C1 (ATC) (Instrument Panel) 16 Way Connector C1 (ATC) - (INSTRUMENT PANEL) 16 WAY MODULE-A/C-HEATER-FRONT (ATC) - (INSTRUMENT PANEL) 16 WAY Front A/C-Heater Module C1 (MTC) (Instrument Panel) 20 Way Connector C1 (MTC) - (INSTRUMENT PANEL) 20 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Front A/C-Heater Module C1 (ATC) (Instrument Panel) 16 Way > Page 7221 MODULE-A/C-HEATER-FRONT (MTC) - (INSTRUMENT PANEL) 20 WAY Front A/C-Heater Module C2 (ATC) (Instrument Panel) 12 Way Connector C2 (ATC) - (INSTRUMENT PANEL) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Front A/C-Heater Module C1 (ATC) (Instrument Panel) 16 Way > Page 7222 MODULE-A/C-HEATER-FRONT (ATC) - (INSTRUMENT PANEL) 12 WAY Front A/C-Heater Module C2 (MTC) (Instrument Panel) 8 Way Connector C2 (MTC) - (INSTRUMENT PANEL) 8 WAY MODULE-A/C-HEATER-FRONT (MTC) - (INSTRUMENT PANEL) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Front A/C-Heater Module C1 (ATC) (Instrument Panel) 16 Way > Page 7223 Front A/C-Heater Module C3 (MTC) (Instrument Panel) 10 Way Connector C3 (MTC) - (INSTRUMENT PANEL) 10 WAY MODULE-A/C-HEATER-FRONT (MTC) - (INSTRUMENT PANEL) 10 WAY Front A/C-Heater Module C3 (ATC) (Instrument Panel) 5 Way Connector C3 (ATC) - (INSTRUMENT PANEL) 5 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Front A/C-Heater Module C1 (ATC) (Instrument Panel) 16 Way > Page 7224 MODULE-A/C-HEATER-FRONT (ATC) - (INSTRUMENT PANEL) 5 WAY Rear A/C-Heater Module (Center Console) 8 Way Connector - (CENTER CONSOLE) 8 WAY MODULE-A/C-HEATER-REAR - (CENTER CONSOLE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Front A/C-Heater Module C1 (ATC) (Instrument Panel) 16 Way > Page 7225 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Single Zone Control Assembly: Description and Operation Front - Manual Single Zone MANUAL SINGLE ZONE The A/C-heater control (1) for the Manual Temperature Control (MTC) single zone heating-A/C system allows one temperature setting for the entire vehicle. All controls are identified by ISO graphic symbols. The A/C-heater control and integral computer is located in the instrument panel and contains: - a rotary control knob for rear window washer operation and rear window wiper speed selection (2). - a slider control knob for temperature control of the discharged air (3). - a rotary control knob for fan speed selection and turning the heater-A/C system off (4). - a rotary control knob for mode control of the discharged air (5). - a push button A/C on/off control (6). The Snowflake button contains an LED that illuminates when the A/C system is in operation. - a push button rear window defogger on/off control (7). The button contains an LED that illuminates when the rear window defogger system is in operation. The A/C-heater control for the manual single zone heating and A/C system is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. Prior to replacing an A/C-heater control, always perform the Actuator Calibration Test to verify the concern is not a heating A/C system issue See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. The A/C-heater control cannot be repaired or adjusted and must be replaced if inoperative or damaged. The illumination lamps (8) and control knobs are available for service replacement. The A/C-heater control utilizes integrated circuitry and information carried on the Controller Area Network (CAN) B bus to monitor many sensors and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the A/C-heater control allows it to control electronic functions and features of the MTC heating-A/C system. The inputs received by the A/C-heater control of the MTC heating-A/C system on the CAN B bus are as follows: - Ambient Air Temperature - Dimming - Engine Coolant Temperature - Refrigerant Pressure - Vehicle Identification Number - Vehicle Odometer - Vehicle Speed The messages broadcasted by the A/C-heater control of the MTC heating-A/C system on the CAN B bus are as follows: - A/C Request - A/C Select - Rear Washer Request - Rear Window Defogger (EBL) Request Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Single Zone > Page 7228 - Rear Wiper Request Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Single Zone > Page 7229 Control Assembly: Description and Operation Front - Manual Single Zone With Rear Heat and A/C MANUAL SINGLE ZONE WITH REAR HEAT AND A/C The A/C-heater control (1) for the Manual Temperature Control (MTC) single zone front and rear heating-A/C system allows both the front and intermediate seat passengers the ability to regulate air temperature as well as fan speed and provides floor outlets near the right rear door and overhead outlets at each intermediate outboard seating position. Primary control for the rear blower motor is on the front A/C-heater control. All controls are identified by ISO graphic symbols. FRONT CONTROL PANEL The front A/C-heater control and integral computer is located in the instrument panel and contains: - a rotary control knob for rear window washer operation and rear window wiper speed selection (2). - a slider control knob for temperature control of the discharged air (3). - a rotary control knob for fan speed selection and turning the heater-A/C system off (4). - a rotary control knob for rear fan speed selection and turning the rear heater-A/C system off (5). - a rotary control knob for mode control of the discharged air (6). - a push button A/C on/off control (7). The Snowflake button contains an LED that illuminates when the A/C system is in operation. - a push button rear window defogger on/off control (8). The button contains an LED that illuminates when the rear window defogger system is in operation. The A/C-heater control for the MTC single zone heating-A/C system is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. Prior to replacing an A/C-heater control, always perform the Actuator Calibration Test to verify the concern is not a heating A/C system issue See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. The A/C-heater control cannot be repaired or adjusted and must be replaced if inoperative or damaged. The illumination lamps (9) and control knobs are available for service replacement. The A/C-heater control utilizes integrated circuitry and information carried on the Controller Area Network (CAN) B bus to monitor many sensors and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the A/C-heater control allows it to control electronic functions and features of the MTC heating-A/C system. The inputs received by the A/C-heater control of the MTC heating-A/C system on the CAN B bus are as follows: - Ambient Air Temperature - Dimming - Engine Coolant Temperature - Refrigerant Pressure - Vehicle Identification Number - Vehicle Odometer - Vehicle Speed The messages broadcasted by the A/C-heater control of the MTC heating-A/C system on the CAN B bus are as follows: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Single Zone > Page 7230 - A/C Request - A/C Select - Rear Washer Request - Rear Window Defogger (EBL) Request - Rear Wiper Request REAR CONTROL PANEL The rear A/C-heater control (1) is located at the rear of the center floor console (2) and allows intermediate seat passengers to adjust rear air distribution, temperature and blower motor speed when the center control knob on the front A/C-heater control (3) is set to the Rear position See: . Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Single Zone > Page 7231 Control Assembly: Description and Operation Front - Automatic Dual Zone With Rear Heat and A/C AUTOMATIC DUAL ZONE WITH REAR HEAT AND A/C The Automatic Temperature Control (ATC) dual zone front heating-A/C system allows both the driver and the front seat passenger the ability to individually regulate air temperature for their side of the vehicle. Primary control for the rear heater-A/C system is also on the front A/C-heater control. An infrared sensor located in the overhead console detects thermal radiation emitted by the front seat occupants and their surroundings. All controls are identified by ISO graphic symbols. FRONT CONTROL PANEL The front A/C-heater control and integral computer (1) is located in the instrument panel and contains the following: - a push button Auto mode control (2). - Two rocker switch controls (3 and 11) to select both of the front and the rear comfort temperatures from 15° to 29° C (60° to 85° F). Comfort temperatures for each zone are shown in the Vacuum-Fluorescent (VF) digital display (4). If the set temperatures are 15° C (60° F) and down (-) is pressed, the A/C-heater control will attempt to achieve the lowest temperature possible, but the display will show LO. If the set temperatures are 29° C (85° F) and up (+) is pressed, the A/C-heater control will attempt to achieve the highest temperature possible, but the display will show HIGH. Temperatures can be displayed in either Metric or Fahrenheit, which is selected from the overhead console. - a rotary control knob with integral push button control for front fan speed selection that can override the automatic controls and on/off control which allows the heating-A/C system to be completely turned off (5). The display is blank when the heater-A/C system is off, except for the ISO rear window defogger symbol when the rear window defogger system is on. - a push button A/C on/off control (6). An ISO Snowflake symbol appears in the display when the A/C system is in operation, whether under manual or automatic control. - a push button air recirculation control (7). An ISO Recirculation symbol appears in the display when the button is pressed, or when the system exceeds 80 percent circulated air under automatic control (Gasoline models) or 100 percent circulated air under automatic control (HEV models), due to high A/C demand. - five push button mode controls (8). An ISO mode symbol appears in the display to show the current mode setting when each button is manually pressed or selected by Auto mode. - a push button rear window defogger on/off control (9). An ISO symbol appears in the display when the rear window defogger system is in operation. The ISO symbol will appear on the display even with the heating-A/C system turned off. - a rotary control knob for rear window washer operation and rear window wiper speed selection (10). - a push button control for rear heating-A/C system operation (12). - two illumination lamps for backlighting of the controls (13). - computer logic that remembers the settings of the controls when the ignition is turned off and retains those settings after a restart. If the system is off when the ignition is turned off it will be off when the engine is restarted, etc. - computer logic that provides variable air recirculation under high temperature and humidity conditions. Because recirculation is generally accompanied by increased fan noise, the proportion of recirculated to outside air gradually approaches full recirculation over a broad temperature range. The A/C-heater control for the ATC front dual zone heating-A/C system is diagnosed using a scan tool See: Testing and Inspection. Prior to replacing the A/C-heater control, always perform the Actuator Calibration Test to verify the concern is not a heating A/C system issue . See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test The front A/C-heater control cannot be adjusted or repaired and must be replaced if inoperative or damaged. The illumination lamps, rear wiper/wash Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Single Zone > Page 7232 control knob and the front fan speed/on/off control knob are available for service replacement. The A/C-heater control utilizes integrated circuitry and information carried on the Controller Area Network (CAN) B bus to monitor many sensors and switch inputs throughout the vehicle. In response to those inputs, the internal circuitry and programming of the A/C-heater control allow it to control electronic functions and features of the ATC heating-A/C system. The inputs received by the A/C-heater control of the ATC heating-A/C system on the CAN B bus are as follows: - Ambient Air Temperature - A/C Compressor Messages (HEV model) - Dimming - A/C Compressor Messages (HEV model) - Heater Auxiliary Coolant Pump Flow (HEV models) - Engine Coolant Temperature - Engine RPM (HEV models) - High Voltage Battery Pack Fan Speed (HEV model) - Ignition Voltage - Infrared Temperature Sensor - Humidity Sensor (HEV models) - Propulsion System A/C Request (HEV model) - Refrigerant Pressure - Vehicle Identification Number - Vehicle Odometer - Vehicle Speed The messages broadcasted by the A/C-heater control of the ATC heating-A/C system on the CAN B bus are as follows: - A/C Request - A/C Select - Climate Control Front Blower Speed (HEV models) - Climate Control Rear Blower Speed (HEV models) - Electric A/C Compressor Request (HEV models) - Heater Auxiliary Coolant Pump Request (HEV models) - High Voltage Battery Pack Fan Speed Limit Request (HEV model) - Rear Washer Request - Rear Window Defogger (EBL) Request - Rear Wiper Request - Sun Sensor Data (Automatic Headlamp Control, when equipped) REAR CONTROL PANEL The rear A/C-heater control (1) is located at the rear of the center floor console (2) and allows intermediate seat passengers to adjust rear temperature and blower motor speed when the control knob on the front A/C-heater control (3) is set to the Rear Manual position See: . Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description and Operation > Front - Manual Single Zone > Page 7233 Control Assembly: Description and Operation Rear DESCRIPTION The rear A/C-heater control (1) for the rear heater-A/C system is located at the rear of the center floor console and allows intermediate seat passengers to adjust rear temperature and blower motor speed when the front A/C-heater control is set to the Rear position, otherwise the front A/C-heater control operates both the front and the rear heater-A/C systems. The rear A/C-heater control contains: - a rotary control knob (2) for rear fan speed selection and turning the rear heater-A/C system off. - a rotary control knob (3) for rear temperature control. With the rear A/C-heater control active, temperature selection dictates the air distribution mode (floor or overhead air) of the rear heater-A/C system. A cool temperature setting directs flow to the overhead outlets and a warm temperature setting to the floor. The rear A/C-heater control is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The rear A/C-heater control cannot be repaired and must be replaced if inoperative or damaged. The illumination lamp (4) and the control knobs are available for service replacement. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C and Heater Control - Removal Control Assembly: Service and Repair A/C and Heater Control - Removal Front REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the center bezel (1) from the instrument panel, disconnect the wire harness connector(s) (2) from the A/C-heater control (3) and place the center bezel on a workbench See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the four screws (1) that secure the A/C-heater control (2) to the instrument panel center bezel (3). 4. Remove the A/C-heater control from the instrument panel center bezel. Rear REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C and Heater Control - Removal > Page 7236 1. Disconnect and isolate the negative battery cable. 2. Using a small screwdriver or similar flat blade tool (1), gently push down on the clip retainer (2) located at each top corner of the rear A/C-heater control (3). Rotate the top of rear A/C-heater control downwards to release the two bottom retaining tabs from the slots in the center floor console. 3. Disconnect the wire harness connector (1) from the rear A/C-heater control (2). 4. Remove the rear A/C-heater control from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C and Heater Control - Removal > Page 7237 Control Assembly: Service and Repair A/C and Heater Control - Installation Front INSTALLATION 1. Position the A/C-heater control (2) into the instrument panel center bezel (3). 2. Install the screws (1) that secure the A/C-heater control to the instrument panel center bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the wire harness connector(s) (2) to the A/C-heater control (3) and install the instrument panel center bezel (1) See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Reconnect the negative battery cable. 5. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Rear INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C and Heater Control - Removal > Page 7238 1. Position the rear A/C-heater control (2) near the center floor console. 2. Connect the wire harness connector (1) to the back of the rear A/C-heater control. 3. Insert the two locator tabs on the bottom of the rear A/C-heater control (1) into the two slots on the bottom edge of the floor console opening (2). 4. Rotate the rear A/C-heater control (3) forward far enough to align the two snap clips on the top of the rear A/C-heater control (4) with the receptacles in the top edge of the floor console opening (5). 5. Using hand pressure, press the top edge of the rear A/C-heater control forward until the two snap clips are fully seated in into the receptacles. 6. Reconnect the negative battery cable. 7. Initiate the Actuator Calibration function using a scan tool See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > A/C and Heater Control - Removal > Page 7239 8. Verify that the Actuator Calibration of the front A/C-heater control has passed. If an Actuator Calibration has not passed correct any errors before proceeding. 9. Rotate the Rear Temperature Selector counter (1) clockwise to the Cold Position. Allow the Selector to remain in the Cold Position for 5 seconds. 10. Rotate the Rear Temperature Selector Clockwise to the Hot Position. Allow the Selector to remain in the Cold Position for 5 seconds. 11. Calibration is now complete. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up Control Module HVAC: Customer Interest A/C - Does Not Cool Sufficiently/Evaporator Ices Up NUMBER: 24-010-08 GROUP: Air Conditioning DATE: December 19, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.04 OR HIGHER. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: FLASH: Evaporator Freeze Up In A/C Equipped Vehicles OVERVIEW: This Bulletin involves reprogramming the Automatic Temperature Control module with new software. MODELS: 2009 (HB) Durango (HEV Only) 2009 (HG) Aspen(HEV Only) NOTE: This bulletin applies to vehicles equipped with HEV engine (sales code EZE) and Automatic Temperature Control (ATC) ATC (sales code HAF). SYMPTOM/CONDITION: Some customers may experience an intermittent condition where air flow from the HVAC vents is warmer than desired while driving with the HVAC system on. This may be due to evaporator freeze up. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) using the appropriate Diagnostic Procedures available in TechCONNECT, verify all ATC systems are functioning as designed. If DTC's are present record them on a repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is experienced or described by the customer, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 9.04 level software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up > Page 7248 "DealerCONNECT > Service> StarSCAN(R) and StarMOBILE(R) tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old HVAC part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the HVAC in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash HVAC" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash HVAC" screen has updated to the new part number. NOTE: Due to the HVAC programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 7. Verify proper performance of HVAC system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up > Page 7249 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up Control Module HVAC: All Technical Service Bulletins A/C - Does Not Cool Sufficiently/Evaporator Ices Up NUMBER: 24-010-08 GROUP: Air Conditioning DATE: December 19, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.04 OR HIGHER. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: FLASH: Evaporator Freeze Up In A/C Equipped Vehicles OVERVIEW: This Bulletin involves reprogramming the Automatic Temperature Control module with new software. MODELS: 2009 (HB) Durango (HEV Only) 2009 (HG) Aspen(HEV Only) NOTE: This bulletin applies to vehicles equipped with HEV engine (sales code EZE) and Automatic Temperature Control (ATC) ATC (sales code HAF). SYMPTOM/CONDITION: Some customers may experience an intermittent condition where air flow from the HVAC vents is warmer than desired while driving with the HVAC system on. This may be due to evaporator freeze up. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) using the appropriate Diagnostic Procedures available in TechCONNECT, verify all ATC systems are functioning as designed. If DTC's are present record them on a repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is experienced or described by the customer, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 9.04 level software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up > Page 7255 "DealerCONNECT > Service> StarSCAN(R) and StarMOBILE(R) tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old HVAC part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the HVAC in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash HVAC" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash HVAC" screen has updated to the new part number. NOTE: Due to the HVAC programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 7. Verify proper performance of HVAC system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up > Page 7256 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical Service Bulletins > Page 7257 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Front Blower Motor Power Module C1 (ATC) Control Module HVAC: Diagrams Front Blower Motor Power Module C1 (ATC) Connector C1 (ATC) MODULE-POWER-BLOWER MOTOR-FRONT (ATC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams > Front Blower Motor Power Module C1 (ATC) > Page 7260 Control Module HVAC: Diagrams Front Blower Motor Power Module C2 (ATC) Connector C2 (ATC) MODULE-POWER-BLOWER MOTOR-FRONT (ATC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description Control Module HVAC: Description and Operation Front Blower Motor Power Module - Description DESCRIPTION A blower motor power module is used on this model when it is equipped with the automatic temperature control (ATC) heating-A/C system. Models equipped with the manual temperature control (MTC) heating-A/C system use a blower motor resistor block, instead of the blower motor power module . The blower motor power module is mounted to the rear of the HVAC housing, directly behind the glove box. The blower motor power module consists of a molded plastic mounting plate with two integral connector receptacles (1). Concealed behind the mounting plate is the power module electronic circuitry and a large finned heat sink (2). The blower motor power module is accessed for service from beneath the right side of the instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description > Page 7263 Control Module HVAC: Description and Operation Front Blower Motor Power Module - Operation OPERATION The blower motor power module is connected to the vehicle electrical system through a dedicated lead and connector of the HVAC wire harness. A second connector receptacle receives the wire harness connector from the blower motor. The blower motor power module allows the microprocessor-based Automatic Temperature Control (ATC) A/C-heater control to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a Pulse Width Modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit that compares the PWM signal voltage to the blower motor feedback voltage. The resulting output drives the power module circuitry, which provides a linear output voltage to change or maintain the desired blower speed. The blower motor power module is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The blower motor power module cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal Control Module HVAC: Service and Repair Front Blower Motor Power Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: The heat sink for the blower motor power module may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor power module, wait five minutes to allow the heat sink to cool before performing diagnosis or service. Failure to take this precaution may result in possible serious injury. 1. Disconnect and isolate the negative battery cable. 2. If equipped with a trim cover (2), remove the two screws (1) that secure the trim cover over the blower motor power module (3) located below the right side of the instrument panel and remove the cover. 3. Disconnect the two wire harness connectors (1) from the blower motor power module (2). 4. Remove the two screws (3) that secure the blower motor power module to the front HVAC housing (4). 5. Remove the blower motor power module from the front HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal > Page 7266 Control Module HVAC: Service and Repair Front Blower Motor Power Module - Installation INSTALLATION 1. Position the blower motor power module (2) into the front HVAC housing (4). 2. Install the two screws (3) that secure the blower motor power module to the front HVAC housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the two wire harness connectors (1) to the blower motor power module. 4. If equipped with a trim cover (2), install the trim cover over the blower motor power module (3) and install the two retaining screws (1). Tighten the screws to 2 Nm (17 in. lbs.). 5. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Refrigerant Line Coupler - Description Coupler HVAC: Description and Operation Refrigerant Line Coupler - Description DESCRIPTION Spring-lock type refrigerant line couplers (6) are used to connect the liquid line (1) and the suction line (3) to the underbody refrigerant lines for the rear heating-A/C system. Secondary retaining clips (2 and 7) are installed over the connected couplers for added protection. The spring-lock refrigerant line couplers require special disconnect tools for disengaging the two coupler halves. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and Operation > Refrigerant Line Coupler - Description > Page 7271 Coupler HVAC: Description and Operation Refrigerant Line Coupler - Operation OPERATION The spring-lock type refrigerant line coupler is held together by a garter spring (6) inside a circular cage (7) on the male half of the fitting (1). When the two coupler halves are connected, the flared end of the female fitting (2) slips behind the garter spring inside the cage on the male fitting. The garter spring and cage prevent the flared end of the female fitting from pulling out of the cage. Some applications use a connection indicator ring (4) to help indicate when the two coupler halves are fully connected. O-rings (8) are used to seal the coupler connections. These O-rings are compatible with R-134a refrigerant and must be replaced with O-rings made of the same material. A secondary retaining clip (3) is installed over the connected coupler (5) for added protection. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Refrigerant Line Coupler - Removal Coupler HVAC: Service and Repair Refrigerant Line Coupler - Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. 1. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 2. Remove the secondary retaining clip from the spring-lock type refrigerant line coupler. 3. Fit the proper size A/C line disconnect tool (Special Tool Kit 7193 or equivalent) over the coupler cage (1). 4. Close the two halves of the A/C line disconnect tool around the coupler (2). NOTE: The garter spring may not release if the A/C line disconnect tool is cocked while pushing it into the coupler cage opening. 5. Push the A/C line disconnect tool into the open side of the coupler cage to expand the garter spring (3). Once the garter spring is expanded, pull on the refrigerant line attached to the female half of the coupler until the flange on the female fitting is separated from the garter spring and cage on the male fitting. 6. Open and remove the A/C line disconnect tool from the refrigerant line coupler (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Refrigerant Line Coupler - Removal > Page 7274 Coupler HVAC: Service and Repair Refrigerant Line Coupler - Installation INSTALLATION 1. Clean any dirt or foreign material from the spring-lock type refrigerant line coupler. 2. Check to make sure that the garter spring (6) is located within the cage (7) of the male half of the refrigerant line coupler (1), and that the garter spring is not damaged. a. If the garter spring is missing, install a new spring by pushing it into the coupler cage opening. b. If the garter spring is damaged, remove it from the coupler cage with a small hook (DO NOT use a screwdriver) and install a new garter spring. NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant coupler is disconnected. Failure to replace the rubber O-ring seals could result in a refrigerant system leak. 3. Install new O-rings (8) on the male half of the refrigerant line coupler. 4. Lubricate the O-rings, and the inside of the female half of the refrigerant line coupler (2) with clean R-134a refrigerant oil. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 5. Position the female half of the coupler over the male half of the coupler. 6. Push together firmly on the two halves of the refrigerant line coupler until the garter spring in the cage on the male half of the coupler snaps over the flanged end on the female half of the coupler. 7. Make sure that the refrigerant line coupler is fully engaged by firmly pulling the refrigerant lines away from each other on both sides of the coupler. 8. Install the secondary retaining clip (3) over connected coupler cage (5). 9. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 10. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed Evaporator Core: Customer Interest A/C - No A/C After Long Trip With Blower On Low Speed NUMBER: 24-004-10 GROUP: Heating & Air Conditioning DATE: April 7, 2010 SUBJECT: No A/C Or Evaporator Freeze Up On Long Trips With Blower In Low Speed Position OVERVIEW: This bulletin involves adding a resistor 470 ohm resistor in the evaporator temperature sensor signal circuit. MODELS: 2004-2009 (HB) Durango 2007-2009 (HG) Aspen NOTE: This bulletin applies to all HB/HG vehicles with A/C (sales code HAA or HAB or HAF). This bulletin does not cover the 2009 HG HEV vehicle. SYMPTOM/CONDITION: The customers may experience poor A/C, little to no A/C operation or reduced airflow from the instrument panel vents. This condition often occurs after a extended drive cycle (greater that 2 hours) with the A/C on and the blower speed is set to the low position. Once the vehicle is shut off or the A/C is turned off for approximately 2 hours the A/C will operate normally. Adding the resistor to the evaporator temperature sensor signal wire allows the A/C Compressor to cycle at a higher temperature more frequently to avoid this condition. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all A/C systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and disconnect the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 - Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Removal Procedures. 2. Using the wiring diagrams available in DealerCONNECT/TechCONNECT locate the evaporator temperature sensor signal wire. Cavity 10 of the C2 black 12 - way connector for ATC systems. Cavity 2 of 20 - way black C1 connector for MTC systems. 3. Measure 76mm (3 inches) down from end of ATC/MTC connector and cut the evaporator temperature sensor signal wire. 4. Using the 2 splice crimps and 2 wire shrink wraps from resistor kit p/n 68064996AA splice in the 470 ohm resistor. Follow the detailed wiring procedures available in DealerCONNECT/TechCONNECT, Refer To the Wiring Tab > 8W-01 Wiring Diagram Information > Wire > Standard Procedure. NOTE: Be sure to use the splice crimps and shrink wrap on wires and resistor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed > Page 7283 5. Install the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Installation Procedures. 6. Using the wiTECH(TM) or StarSCAN(R) erase all DTC. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed Evaporator Core: All Technical Service Bulletins A/C - No A/C After Long Trip With Blower On Low Speed NUMBER: 24-004-10 GROUP: Heating & Air Conditioning DATE: April 7, 2010 SUBJECT: No A/C Or Evaporator Freeze Up On Long Trips With Blower In Low Speed Position OVERVIEW: This bulletin involves adding a resistor 470 ohm resistor in the evaporator temperature sensor signal circuit. MODELS: 2004-2009 (HB) Durango 2007-2009 (HG) Aspen NOTE: This bulletin applies to all HB/HG vehicles with A/C (sales code HAA or HAB or HAF). This bulletin does not cover the 2009 HG HEV vehicle. SYMPTOM/CONDITION: The customers may experience poor A/C, little to no A/C operation or reduced airflow from the instrument panel vents. This condition often occurs after a extended drive cycle (greater that 2 hours) with the A/C on and the blower speed is set to the low position. Once the vehicle is shut off or the A/C is turned off for approximately 2 hours the A/C will operate normally. Adding the resistor to the evaporator temperature sensor signal wire allows the A/C Compressor to cycle at a higher temperature more frequently to avoid this condition. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all A/C systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and disconnect the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 - Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Removal Procedures. 2. Using the wiring diagrams available in DealerCONNECT/TechCONNECT locate the evaporator temperature sensor signal wire. Cavity 10 of the C2 black 12 - way connector for ATC systems. Cavity 2 of 20 - way black C1 connector for MTC systems. 3. Measure 76mm (3 inches) down from end of ATC/MTC connector and cut the evaporator temperature sensor signal wire. 4. Using the 2 splice crimps and 2 wire shrink wraps from resistor kit p/n 68064996AA splice in the 470 ohm resistor. Follow the detailed wiring procedures available in DealerCONNECT/TechCONNECT, Refer To the Wiring Tab > 8W-01 Wiring Diagram Information > Wire > Standard Procedure. NOTE: Be sure to use the splice crimps and shrink wrap on wires and resistor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed > Page 7289 5. Install the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Installation Procedures. 6. Using the wiTECH(TM) or StarSCAN(R) erase all DTC. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Front A/C Evaporator - Description Evaporator Core: Description and Operation Front A/C Evaporator - Description DESCRIPTION The A/C evaporator (1) for the front heating-A/C system is located within the front HVAC housing (2), behind the instrument panel. The A/C evaporator and insulator (3) are positioned in the HVAC housing so that all air entering the housing must pass over the evaporator fins before it is distributed through the heating-A/C system ducts and outlets. However, air passing over the evaporator fins will only be conditioned when the A/C compressor is engaged and circulating refrigerant through the A/C evaporator. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Front A/C Evaporator - Description > Page 7292 Evaporator Core: Description and Operation Front A/C Evaporator - Operation OPERATION Refrigerant enters the A/C evaporator from the A/C expansion valve as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the A/C evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the A/C evaporator. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line or expansion valve is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C evaporator has no serviceable parts except for the O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C expansion valve is removed from the A/C evaporator. The A/C evaporator cannot be repaired and must be replaced if leaking or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Front A/C Evaporator - Description > Page 7293 Evaporator Core: Description and Operation Rear A/C Evaporator - Description DESCRIPTION The A/C evaporator (1) for the rear heating-A/C system is mounted within the rear heater-A/C housing, which is located behind the right interior quarter panel trim. The rear A/C evaporator and its insulator (4) are positioned within the rear heater-A/C housing so that all air entering the housing must pass over the evaporator fins before it is distributed through the rear heating-A/C system ducts and outlets. A tapping block (2) and O-ring seals (3) are used to connect and seal the rear A/C expansion valve to the rear A/C evaporator. The rear A/C evaporator can only be serviced by removing and disassembling the rear heater-A/C housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Front A/C Evaporator - Description > Page 7294 Evaporator Core: Description and Operation Rear A/C Evaporator - Operation OPERATION Refrigerant enters the rear A/C evaporator from the rear A/C expansion valve as a low-temperature, low-pressure mixture of liquid and gas. As air flows over the fins of the rear A/C evaporator, the humidity in the air condenses on the fins, and the heat from the air is absorbed by the refrigerant. Heat absorption causes the refrigerant to boil and vaporize. The refrigerant becomes a low-pressure gas when it leaves the rear A/C evaporator. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line or expansion valve is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C evaporator has no serviceable parts except for the O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the rear A/C expansion valve is removed from the rear A/C evaporator. The rear A/C evaporator cannot be repaired and must be replaced if leaking or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator - Removal Evaporator Core: Service and Repair Front A/C Evaporator - Removal REMOVAL 1. Remove the HVAC housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal. 2. Disassemble the HVAC housing See: Housing Assembly HVAC/Service and Repair/Overhaul/Disassembly/Front HVAC Housing. 3. Remove the probe of the evaporator temperature sensor from the fins of the A/C evaporator See: Evaporator Temperature Sensor / Switch/Service and Repair/Front Evaporator Temperature Sensor - Removal. 4. Carefully lift the A/C evaporator (1) out of the lower half of the HVAC housing (2). 5. If required, remove the evaporator insulator (3) from around the A/C evaporator. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator - Removal > Page 7297 Evaporator Core: Service and Repair Front A/C Evaporator - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: If only the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line or expansion valve is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. 1. Install the A/C evaporator (1) into the lower half of the HVAC housing (2). Make sure that the evaporator drain is clean and unrestricted and that the evaporator insulator (3) is properly installed. 2. Install the probe for the evaporator temperature sensor into the fins of the A/C evaporator See: Evaporator Temperature Sensor / Switch/Service and Repair/Front Evaporator Temperature Sensor - Installation 3. Assemble the HVAC housing See: Housing Assembly HVAC/Service and Repair/Overhaul/Assembly/Front HVAC Housing. 4. Install the HVAC housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Installation. 5. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator - Removal > Page 7298 Evaporator Core: Service and Repair Rear A/C Evaporator - Removal REMOVAL 1. Remove the rear heater-A/C housing and place it on a workbench See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal. 2. Disassemble the rear heater-A/C housing as necessary to gain access to the rear A/C evaporator (1) See: Housing Assembly HVAC/Service and Repair/Overhaul/Disassembly/Front HVAC Housing. NOTE: If the insulator around the A/C evaporator or evaporator tubes is deformed or damaged, the insulator must be replaced. 3. Carefully remove the rear A/C evaporator out of the outboard half of the rear heater-A/C housing (3). NOTE: If the rubber seal is deformed or damaged, the seal must be replaced. 4. If required, remove the rubber seal (2) from the rear heater-A/C housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and Repair > Front A/C Evaporator - Removal > Page 7299 Evaporator Core: Service and Repair Rear A/C Evaporator - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: If only the A/C evaporator is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: If the insulator around the A/C evaporator or evaporator tubes is deformed or damaged, the insulator must be replaced. 1. Carefully install the rear A/C evaporator (1) into the outboard half of the rear heater-A/C housing (3). NOTE: If the rubber seal is deformed or damaged, the seal must be replaced. 2. If removed, install the rubber seal (2) into the groove in the rear heater-A/C housing. 3. Assemble the rear heater-A/C housing See: Housing Assembly HVAC/Service and Repair/Overhaul/Assembly/Front HVAC Housing. 4. Install the rear heater-A/C housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Installation. 5. If the rear A/C evaporator is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed Evaporator Temperature Sensor / Switch: Customer Interest A/C - No A/C After Long Trip With Blower On Low Speed NUMBER: 24-004-10 GROUP: Heating & Air Conditioning DATE: April 7, 2010 SUBJECT: No A/C Or Evaporator Freeze Up On Long Trips With Blower In Low Speed Position OVERVIEW: This bulletin involves adding a resistor 470 ohm resistor in the evaporator temperature sensor signal circuit. MODELS: 2004-2009 (HB) Durango 2007-2009 (HG) Aspen NOTE: This bulletin applies to all HB/HG vehicles with A/C (sales code HAA or HAB or HAF). This bulletin does not cover the 2009 HG HEV vehicle. SYMPTOM/CONDITION: The customers may experience poor A/C, little to no A/C operation or reduced airflow from the instrument panel vents. This condition often occurs after a extended drive cycle (greater that 2 hours) with the A/C on and the blower speed is set to the low position. Once the vehicle is shut off or the A/C is turned off for approximately 2 hours the A/C will operate normally. Adding the resistor to the evaporator temperature sensor signal wire allows the A/C Compressor to cycle at a higher temperature more frequently to avoid this condition. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all A/C systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and disconnect the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 - Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Removal Procedures. 2. Using the wiring diagrams available in DealerCONNECT/TechCONNECT locate the evaporator temperature sensor signal wire. Cavity 10 of the C2 black 12 - way connector for ATC systems. Cavity 2 of 20 - way black C1 connector for MTC systems. 3. Measure 76mm (3 inches) down from end of ATC/MTC connector and cut the evaporator temperature sensor signal wire. 4. Using the 2 splice crimps and 2 wire shrink wraps from resistor kit p/n 68064996AA splice in the 470 ohm resistor. Follow the detailed wiring procedures available in DealerCONNECT/TechCONNECT, Refer To the Wiring Tab > 8W-01 Wiring Diagram Information > Wire > Standard Procedure. NOTE: Be sure to use the splice crimps and shrink wrap on wires and resistor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed > Page 7308 5. Install the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Installation Procedures. 6. Using the wiTECH(TM) or StarSCAN(R) erase all DTC. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed Evaporator Temperature Sensor / Switch: All Technical Service Bulletins A/C - No A/C After Long Trip With Blower On Low Speed NUMBER: 24-004-10 GROUP: Heating & Air Conditioning DATE: April 7, 2010 SUBJECT: No A/C Or Evaporator Freeze Up On Long Trips With Blower In Low Speed Position OVERVIEW: This bulletin involves adding a resistor 470 ohm resistor in the evaporator temperature sensor signal circuit. MODELS: 2004-2009 (HB) Durango 2007-2009 (HG) Aspen NOTE: This bulletin applies to all HB/HG vehicles with A/C (sales code HAA or HAB or HAF). This bulletin does not cover the 2009 HG HEV vehicle. SYMPTOM/CONDITION: The customers may experience poor A/C, little to no A/C operation or reduced airflow from the instrument panel vents. This condition often occurs after a extended drive cycle (greater that 2 hours) with the A/C on and the blower speed is set to the low position. Once the vehicle is shut off or the A/C is turned off for approximately 2 hours the A/C will operate normally. Adding the resistor to the evaporator temperature sensor signal wire allows the A/C Compressor to cycle at a higher temperature more frequently to avoid this condition. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all A/C systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and disconnect the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 - Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Removal Procedures. 2. Using the wiring diagrams available in DealerCONNECT/TechCONNECT locate the evaporator temperature sensor signal wire. Cavity 10 of the C2 black 12 - way connector for ATC systems. Cavity 2 of 20 - way black C1 connector for MTC systems. 3. Measure 76mm (3 inches) down from end of ATC/MTC connector and cut the evaporator temperature sensor signal wire. 4. Using the 2 splice crimps and 2 wire shrink wraps from resistor kit p/n 68064996AA splice in the 470 ohm resistor. Follow the detailed wiring procedures available in DealerCONNECT/TechCONNECT, Refer To the Wiring Tab > 8W-01 Wiring Diagram Information > Wire > Standard Procedure. NOTE: Be sure to use the splice crimps and shrink wrap on wires and resistor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed > Page 7314 5. Install the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Installation Procedures. 6. Using the wiTECH(TM) or StarSCAN(R) erase all DTC. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Page 7315 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Page 7316 Evaporator Temperature Sensor / Switch: Diagrams Connector - 2 WAY SENSOR-EVAPORATOR TEMPERATURE - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Front Evaporator Temperature Sensor - Description Evaporator Temperature Sensor / Switch: Description and Operation Front Evaporator Temperature Sensor - Description DESCRIPTION The evaporator temperature sensor (1) is an electrical thermistor located within a molded plastic case that is inserted into the HVAC housing (2) to measure the temperature of the conditioned air downstream of the A/C evaporator (3). Two terminals within the connector receptacle connect the sensor to the vehicle electrical system through a wire lead and connector of the HVAC wire harness. NOTE: Cutaway of typical HVAC housing shown for clarity in illustration. The external location of the evaporator temperature sensor allows the sensor to be removed or installed without disturbing the refrigerant in the A/C system. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Front Evaporator Temperature Sensor - Description > Page 7319 Evaporator Temperature Sensor / Switch: Description and Operation Front Evaporator Temperature Sensor - Operation OPERATION The evaporator temperature sensor monitors the temperature of the conditioned air downstream of the A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. On gasoline engine equipped models, the A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature and that conditions are correct to broadcast an A/C request message on the Controller Area Network (CAN) B bus, where it is read by the Front Control Module (FCM). The FCM then requests the Powertrain Control Module (PCM) to cycle the A/C compressor clutch as necessary over the CAN C bus. On Hybrid Electric Vehicle (HEV) models, the A/C-heater control calculates an evaporator temperature target based on A/C load. This target temperature is compared with the actual evaporator temperature sensor value. Based on this comparison, the A/C-heater control sends out a compressor target RPM speed over the CAN B bus to the FCM. The FCM then ports the target message to the electric A/C compressor over the CAN C bus. If the A/C-heater control does not receive the electric A/C compressor messages, a Diagnostic Trouble Code (DTC) will be set. The evaporator temperature sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The evaporator temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Front Evaporator Temperature Sensor - Removal Evaporator Temperature Sensor / Switch: Service and Repair Front Evaporator Temperature Sensor - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage during this service procedure. 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 3. Disconnect the HVAC wire harness connector (1) from the evaporator temperature sensor (2) located on the top of the HVAC housing (3) near the blend door actuator (4). 4. Remove the evaporator temperature sensor from the HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Front Evaporator Temperature Sensor - Removal > Page 7322 Evaporator Temperature Sensor / Switch: Service and Repair Front Evaporator Temperature Sensor - Installation INSTALLATION 1. Install the evaporator temperature sensor (2) into the opening in the HVAC housing (3) near the blend door actuator (4). 2. Connect the HVAC wire harness connector (1) to the evaporator temperature sensor. 3. Install the instrument panel assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Installation. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > A/C Expansion Valve - Description Expansion Valve: Description and Operation A/C Expansion Valve - Description Front DESCRIPTION NOTE: Typical A/C expansion valve shown. The A/C expansion valve controls the amount of refrigerant entering the A/C evaporator and is of a thermostatic expansion valve (TXV) design. The A/C expansion valve consists of an aluminum H-valve type body (1) with an integral thermal sensor (2) and is located at the dash panel between the A/C refrigerant lines and the A/C evaporator. Rear DESCRIPTION The rear A/C expansion valve controls the amount of refrigerant entering the rear A/C evaporator. The rear A/C expansion valve is of a thermostatic expansion valve (TXV) design and consists of an aluminum H-valve type body (1) with an inlet port (2), outlet port (3) and an integral thermal sensor (4). The rear A/C expansion valve is located between the rear extension tubes and the rear A/C evaporator at the rear of the heater-A/C housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Description and Operation > A/C Expansion Valve - Description > Page 7327 Expansion Valve: Description and Operation A/C Expansion Valve - Operation Front OPERATION The A/C expansion valve controls the flow of high-pressure, low temperature liquid refrigerant entering the expansion valve and converts it into a low-pressure, low-temperature mixture of liquid and gas before it enters the A/C evaporator. To meet the vehicles A/C cooling requirements, a mechanical sensor is used in the A/C expansion valve to monitor the temperature and pressure of the refrigerant leaving the A/C evaporator and then adjust the inlet port orifice size to allow only the proper amount of refrigerant to enter the evaporator. Controlling the refrigerant flow through the A/C evaporator ensures that none of the refrigerant leaving the evaporator is still in a liquid state, which could damage the A/C compressor. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line or expansion valve is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C expansion valve is factory calibrated and cannot be adjusted or repaired and must be replaced if inoperative or damaged. Rear OPERATION The rear A/C expansion valve controls the flow of high-pressure, low temperature liquid refrigerant entering the expansion valve and converts it into a low-pressure, low-temperature mixture of liquid and gas before it enters the rear A/C evaporator. To meet the vehicles A/C cooling requirements, a mechanical sensor is used in the rear A/C expansion valve to monitor the temperature and pressure of the refrigerant leaving the rear A/C evaporator and then adjust the inlet port orifice size to allow only the proper amount of refrigerant to enter the evaporator. Controlling the refrigerant flow through the rear A/C evaporator ensures that none of the refrigerant leaving the evaporator is still in a liquid state, which could damage the A/C compressor. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line or expansion valve is disconnected. Failure to replace the rubber O-ring seals and metal gaskets may result in a refrigerant system leak. The rear A/C expansion valve is factory calibrated and cannot be adjusted or repaired and must be replaced if inoperative or damaged Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Testing and Inspection > Front Expansion Valve: Testing and Inspection Front A/C EXPANSION VALVE WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. NOTE: Liquid CO2 is required to test the A/C expansion valve. This material is available from most welding supply facilities. Liquid CO2 is also available from companies which service and sell fire extinguishers. DO NOT use R-134a or R-12 refrigerant for this test. When testing the A/C expansion valve, the work area and the vehicle temperature must be 21° to 27° C (70° to 85° F). To test the expansion valve: NOTE: The A/C expansion valve should only be tested following testing of the A/C compressor. 1. Verify the A/C compressor is operating to design standards See: Testing and Inspection/Component Tests and General Diagnostics. 2. Connect a charging station or manifold gauge set to the refrigerant system service ports. Verify the refrigerant charge level. 3. Close all doors and windows. 4. Set the A/C-heater controls to the following positions: - temperature control to full warm - mode control to floor - blower motor control to high speed 5. Start the engine and allow it to idle. After the engine has reached normal operating temperature, allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the A/C evaporator. 6. With passenger compartment heated up, set the A/C-heater controls to the following positions: - A/C compressor engaged - temperature control to full cold - mode control to panel - blower motor control to high speed 7. With the correct refrigerant charge level, the high pressure gauge should read approximately 930 kPa to 1725 kPa (135 psi to 250 psi) and the low pressure gauge should read approximately 175 kPa to 380 kPa (25 psi to 55 psi). If OK, go to 8. If not OK, replace the faulty A/C expansion valve. WARNING: Protect the skin and eyes from exposure to liquid CO2 or possible serious injury can result. 8. If the low pressure gauge reads within the specified range, freeze the A/C expansion valve for 30 seconds using liquid CO2 or another suitable super-cold material. Do not spray R-134a or R-12 refrigerant on the A/C expansion valve for this test. The low pressure gauge reading should drop by 70 kPa (10 psi). If OK, go to 9 If not OK, replace the faulty A/C expansion valve. 9. Allow the expansion valve control head to thaw. The low pressure gauge reading should stabilize at approximately 175 kPa to 380 kPa (25 psi to 55 psi). If not OK, replace the faulty A/C expansion valve. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Testing and Inspection > Front > Page 7330 Expansion Valve: Testing and Inspection Rear A/C EXPANSION VALVE - REAR WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. NOTE: The rear A/C expansion valve should only be tested following testing of the A/C compressor. NOTE: Liquid CO2 is required to test the rear A/C expansion valve. This material is available from most welding supply facilities. Liquid CO2 is also available from companies which service and sell fire extinguishers. When testing the rear A/C expansion valve, the work area and the vehicle temperature must be 21° to 27° C (70° to 85° F). To test the expansion valve: 1. Connect a charging station or manifold gauge set to the refrigerant system service ports. Verify the refrigerant charge level. 2. Close all doors, windows and vents to the passenger compartment. 3. Set the A/C-heater controls for the rear heating-A/C system so that the A/C compressor is operating, the rear temperature control is in the highest temperature position, and the blower motor is operating at the highest speed. 4. Start the engine and allow it to idle. After the engine has reached normal operating temperature, allow the passenger compartment to heat up. This will create the need for maximum refrigerant flow into the rear A/C evaporator. 5. If the refrigerant charge is sufficient, the discharge (high pressure) gauge should read 827 kPa to 1655 kPa (120 psi to 240 psi). The suction (low pressure) gauge should read 207 kPa to 345 kPa (30 psi to 50 psi). If OK, go to 6. If not OK, replace the inoperative rear A/C expansion valve. WARNING: Protect the skin and eyes from exposure to liquid CO2 or possible serious injury can result. 6. If the suction (low pressure) gauge reads within the specified range, freeze the rear A/C expansion valve for 30 seconds using liquid CO2 or another suitable super-cold material. Do not spray R-134a or R-12 refrigerant on the rear A/C expansion valve for this test. The suction (low pressure) gauge reading should drop by 69 kPa (10 psi). If OK, go to 7 If not OK, replace the inoperative rear A/C expansion valve. 7. Allow the rear expansion valve control head to thaw. The suction (low pressure) gauge reading should stabilize at 207 kPa to 345 kPa (30 psi to 50 psi). If not OK, replace the inoperative rear A/C expansion valve. 8. When expansion valve testing is complete, test the overall A/C system performance See: Testing and Inspection/Component Tests and General Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > A/C Expansion Valve - Removal Expansion Valve: Service and Repair A/C Expansion Valve - Removal Front REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 4. Raise and support the vehicle. 5. Remove the right front wheelhouse splash shield. NOTE: It is not necessary to remove the front A/C liquid line from the receiver drier when removing the A/C lines from the A/C expansion valve. If care is used, the liquid line can be flexed to gain access to the expansion valve. This also applies to the rear A/C lines, if equipped. 6. Carefully remove the A/C suction line (1) and the A/C liquid line (2) from the A/C expansion valve (3) See: Hose/Line HVAC/Service and Repair/Removal and Replacement/A/C Suction Line - Removal or See: Hose/Line HVAC/Service and Repair/Removal and Replacement/A/C Liquid Line - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > A/C Expansion Valve - Removal > Page 7333 7. Remove the two bolts (1) that secure the A/C expansion valve (2) to the evaporator tube tapping block (3). 8. Remove the A/C expansion valve from the evaporator tube tapping block and remove and discard the O-ring seals. 9. Install plugs in, or tape over the opened evaporator tube fittings and all expansion valve ports. Rear REMOVAL 1. Remove the rear heater-A/C housing and place it on a workbench See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal. NOTE: If the foam seal for the flange is deformed or damaged, the seal be replaced. 2. Carefully remove the foam seal (3) from the rear heater core tube and evaporator line flange (2). 3. Remove the screw (4) that secures the rear heater core tube and evaporator line flange to the outboard side of the rear heater-A/C housing (5). 4. Disengage the retaining tab (1) that secures the rear heater core tube and evaporator line flange to the rear heater-A/C housing and remove the flange. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > A/C Expansion Valve - Removal > Page 7334 5. Remove the two bolts (1) that secure the rear evaporator extension lines (3) and the rear A/C expansion valve (2) to the rear evaporator tapping block (4). 6. Disconnect the rear evaporator extension lines from the rear A/C expansion valve (2) and remove the lines from the rear heater-A/C housing. 7. Disconnect the rear A/C expansion valve from the rear evaporator tapping block. 8. Remove and discard the O-ring seals and install plugs in, or tape over the opened extension line fittings and expansion valve and evaporator ports. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > A/C Expansion Valve - Removal > Page 7335 Expansion Valve: Service and Repair A/C Expansion Valve - Installation Front INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: Always use ND-11 Polyester (POE) oil from Mopar(R) in Hybrid Electric Vehicle (HEV) models. Never use Polyalkylene Glycol (PAG) oil in an HEV model. See Refrigerant Oil for more information. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. 1. Remove the tape or plugs from the evaporator tube fittings and all of the expansion valve ports. 2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the evaporator tube fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Install the A/C expansion valve (2) onto the evaporator tube tapping block (3). 4. Install the two bolts (1) that secure the A/C expansion valve to the evaporator tube tapping block. Tighten the bolts to 11 Nm (97 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > A/C Expansion Valve - Removal > Page 7336 CAUTION: Use care when installing the A/C lines to the A/C expansion valve. Carefully align the tube ends with the valve prior to tightening the A/C line retaining nut or damage to the sealing rings and tube ends may occur. 5. Install the A/C suction line (1) and the A/C liquid line (2) to the A/C expansion valve (3) See: Hose/Line HVAC/Service and Repair/Removal and Replacement/A/C Suction Line - Installation or See: Hose/Line HVAC/Service and Repair/Removal and Replacement/A/C Liquid Line - Installation. 6. Install the right front wheelhouse splash shield. 7. Lower the vehicle. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 8. On HEV models, reconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 9. On gasoline only models, reconnect the negative battery cable. 10. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 11. Adjust the refrigerant oil level See: Specifications/Capacity Specifications/Refrigerant Oil Capacity. 12. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Rear INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line or expansion valve is disconnected. Failure to replace the rubber O-ring seals could result in a refrigerant system leak. 1. Remove the tape or plugs from the rear evaporator tube and extension line fittings and all rear expansion valve ports. 2. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto rear evaporator tube and extension line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Install the rear A/C expansion valve (2) onto the rear A/C evaporator tube tapping block (4). 4. Connect the rear evaporator extension lines (3) to the rear A/C expansion valve and install the two retaining bolts (1). Tighten the bolts to 11 Nm (97 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > A/C Expansion Valve - Removal > Page 7337 5. Position the rear heater core tube and evaporator line flange (2) to the outboard side of the rear heater-A/C housing (5) and engage the retaining tab (1). Make sure the tab is fully engaged to the housing. 6. Install the screw (4) that secures the rear heater core tube and evaporator line flange to the inboard side of the rear heater-A/C housing. Tighten the screw to 2 Nm (17 in. lbs.). NOTE: If the foam seal for the flange is deformed or damaged, the seal be replaced. 7. Carefully install the foam seal (3) onto the rear heater core tube and evaporator line flange. 8. Install the rear heater-A/C housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Front Heater Core - Description Heater Core: Description and Operation Front Heater Core - Description DESCRIPTION The heater core (1) for the front heating-A/C system is located in the front HVAC housing, behind the instrument panel. It is a heat exchanger made of rows of tubes and fins. The heater core is secured to the HVAC housing by a plastic retaining bracket and screws. The heater core tubes (2) are attached to the top of the heater core by metal retaining clips (3) and O-ring seals. The heater core tubes are not serviced separately from the heater core. The HVAC housing must be removed from the vehicle to service the heater core. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Front Heater Core - Description > Page 7342 Heater Core: Description and Operation Front Heater Core - Operation OPERATION Engine coolant is circulated through the heater hoses to the heater core at all times. As the coolant flows through the heater core, heat is removed from the engine and is transferred to the heater core tubes and fins. Air directed through the heater core picks up the heat from the heater core fins. The blend-air door(s) allows control of the heater output air temperature by regulating the amount of air flowing through the heater core. The blower motor speed controls the volume of air flowing through the HVAC housing. The heater core cannot be repaired and must be replaced if restricted, leaking or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Front Heater Core - Description > Page 7343 Heater Core: Description and Operation Rear Heater Core - Description DESCRIPTION The rear heater core (1) is a heat exchanger made of rows of tubes and fins. The rear heater core is located in the rear heater-A/C housing behind the right interior quarter trim panel and is retained in the housing by a plastic mounting bracket and a screw. The heater core tubes (3) are attached to the heater core by metal retaining clamps (2) and rubber O-ring seals and are secured to the rear heater-A/C housing by a plastic flange. The heater core tubes are not serviced separately from the rear heater core. The rear heater-A/C housing must be removed from the vehicle to service the rear heater core. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Description and Operation > Front Heater Core - Description > Page 7344 Heater Core: Description and Operation Rear Heater Core - Operation OPERATION Engine coolant is circulated through heater hoses and tubes to the rear heater core at all times. As the coolant flows through the heater core, heat removed from the engine is transferred to the heater core fins and the air directed through the heater core picks up the heat from the fins. The rear blend air door allows control of the rear heater output air temperature by controlling the amount of air flowing through or around the rear heater core. The rear blower motor speed controls the volume of air flowing through the rear heater-A/C housing. The rear heater core cannot be repaired and must be replaced if inoperative, leaking or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal Heater Core: Service and Repair Front Heater Core - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: The heater core tubes are not serviced separately from the heater core. The heater core tubes should not be repositioned, loosened or removed from the heater core. Failure to follow this warning could result in a coolant leak and possible serious or fatal injury. NOTE: Gasoline model shown in illustrations. HEV model similar. 1. Remove the front HVAC housing (1) and place it on a workbench See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal. 2. Disconnect the HVAC wire harness (2) from the recirculation door actuator (3). 3. Remove the screws (4) that secure the air inlet housing (5) to the HVAC housing. 4. Remove the air inlet housing from the HVAC housing. 5. Carefully remove the foam seal (1) from the flange on the HVAC housing (2). If the seal is deformed or damaged, it must be replaced. 6. Remove the screw (3) that secures the heater core tube retaining bracket (4) to the top of the HVAC housing. 7. Remove the heater core tube retaining bracket from the HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 7347 8. Remove the two screws (1) that secure the HVAC housing retaining bracket (2) to the top of the HVAC housing (3) and remove the bracket. 9. Remove the two screws (4) that secure the heater core retaining bracket (5) to the top of the HVAC housing and remove the bracket. 10. Carefully remove the heater core (6) and heater core tubes as an assembly from the top of the HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 7348 Heater Core: Service and Repair Front Heater Core - Installation INSTALLATION WARNING: The heater core tubes are not serviced separately from the heater core. The heater core tubes should not be repositioned, loosened or removed from the heater core. Failure to follow this warning could result in a coolant leak and possible serious or fatal injury. NOTE: Gasoline model shown in illustrations. HEV model similar. 1. Carefully install the heater core (6) into the top of the HVAC housing (3). Make sure that the heater core insulator is properly positioned. 2. Install the two screws (4) that secure the heater core retaining bracket (5) to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 3. Install the HVAC housing bracket (2) to the top of HVAC housing. 4. Install the two screws (1) that secure the HVAC housing bracket to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 5. Install the heater core tube retaining bracket (4) to the top of the HVAC housing (2). 6. Install the screw (3) that secures the heater core tube retaining bracket to the HVAC housing. Tighten the screw to 2.2 Nm (20 in. lbs.). 7. Install the foam seal (1) to the flange on the HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 7349 8. Install the air inlet housing (5) onto the top of the HVAC housing (1). 9. Install the screws (4) that secure the air inlet housing to the HVAC housing. Make sure the HVAC wire harness retainer is properly installed. 10. Connect the HVAC wire harness (2) to the recirculation door actuator (3). 11. Install the front HVAC housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Installation. 12. Reconnect the negative battery cable. 13. If the heater core is being replaced, flush the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 14. Refill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 15. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 16. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 7350 Heater Core: Service and Repair Rear Heater Core - Removal REMOVAL WARNING: The heater core tubes are not serviced separately from the rear heater core. The heater core tubes should not be repositioned, loosened or removed from the rear heater core. Failure to follow this warning may result in a coolant leak and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the rear heater-A/C housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Removal. NOTE: If the foam seal for the flange is deformed or damaged, the seal be replaced. 3. Carefully remove the foam seal (3) from the rear heater core tube and evaporator line flange (2). 4. Remove the screw (4) that secures the rear heater core tube and evaporator line flange to the outboard side of the rear heater-A/C housing (5). 5. Disengage the retaining tab (1) that secures the rear heater core tube and evaporator line flange to the rear heater-A/C housing and remove the flange. 6. Remove the screw (3) that secures the rear heater core retaining bracket (4) to the rear heater-A/C housing (1) and remove the bracket. NOTE: If a foam seal around the heater core is deformed or damaged, the seal must be replaced. 7. Carefully pull the rear heater core (2) out of the inboard side of the rear heater-A/C housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Front Heater Core - Removal > Page 7351 Heater Core: Service and Repair Rear Heater Core - Installation INSTALLATION WARNING: The heater core tubes are not serviced separately from the rear heater core. The heater core tubes should not be repositioned, loosened or removed from the rear heater core. Failure to follow this warning may result in a coolant leak and possible serious or fatal injury. NOTE: If a foam seal on the rear heater core is deformed or damaged, the seal must be replaced. 1. Install the rear heater core (2) into the inboard side of the rear heater-A/C housing (1). Make sure that the foam seals around the heater core are properly installed. 2. Install the rear heater core retaining bracket (4). 3. Install the screw (3) that secures the rear heater core retaining bracket to the rear heater-A/C housing. Tighten the screw to 2 Nm (17 in. lbs.). 4. Position the rear heater core tube and evaporator line flange (2) to the outboard side of the rear heater-A/C housing (5) and engage the retaining tab (1). Make sure the tab is fully engaged to the housing. 5. Install the screw (4) that secures the rear heater core tube and evaporator line flange to the inboard side of the rear heater-A/C housing. Tighten the screw to 2 Nm (17 in. lbs.). NOTE: If the foam seal for the flange is deformed or damaged, the seal be replaced. 6. Carefully install the foam seal (3) onto the rear heater core tube and evaporator line flange. 7. Install the rear heater-A/C housing See: Housing Assembly HVAC/Service and Repair/Removal and Replacement/Front HVAC Housing Installation. 8. Reconnect the negative battery cable. 9. If the rear heater core is being replaced, flush the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > High Pressure Relief Valve - Operation High Pressure Safety Valve HVAC: Description and Operation High Pressure Relief Valve Operation HIGH PRESSURE RELIEF VALVE The high pressure relief valve vents refrigerant from the A/C system when a discharge pressure of 3445 to 4135 kPa (500 to 600 psi) or above is reached. The high pressure relief valve closes with a minimum discharge pressure of 2756 kPa (400 psi) is reached. The high pressure relief valve should not open when the A/C system is operating correctly. If the high pressure relief valve vents refrigerant, there is most likely a problem within the A/C refrigerant system. The high pressure relief valve vents only enough refrigerant to reduce the A/C system pressure, and then re-seats itself. If the high pressure relief valve vents refrigerant, see the A/C System Diagnosis chart See: Testing and Inspection/Component Tests and General Diagnostics. The high pressure relief valve is factory-calibrated and cannot be adjusted or repaired, and must not be removed or otherwise disturbed. The valve is only serviced as a part of the A/C compressor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description Hose/Line HVAC: Description and Operation A/C Discharge Line - Description DESCRIPTION The A/C discharge line (1) is the refrigerant line that carries refrigerant from the A/C compressor to the A/C condenser (2) and is secured to the condenser fan shroud (4) by a plastic retainer (3). The A/C discharge line has an integral fitting for the A/C pressure transducer (5) See: Refrigerant Pressure Sensor / Switch/Description and Operation/Front A/C Pressure Transducer - Description. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C discharge line has no serviceable parts except for the rubber O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C discharge line is disconnected. The A/C discharge line cannot be repaired and must be replaced if leaking or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 7360 Hose/Line HVAC: Description and Operation A/C Liquid Line - Description Front DESCRIPTION The A/C liquid line is the refrigerant line that carries refrigerant from the A/C condenser to the A/C evaporator. The A/C liquid line is serviced in two sections. The front section of the liquid line (1) connects between the A/C condenser and the receiver/drier (2). The rear section of the liquid line (3) connects between the A/C receiver/drier and the A/C expansion valve (7) and includes the high side service port (5) and a tapping plate (8) that secures the suction line (9) to the A/C expansion valve. On models equipped with the rear heating-A/C system, the rear section of the A/C liquid line also includes an extension tube that connects the liquid line to the underbody lines . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C liquid line has no serviceable parts except for the rubber O-ring seals, high-side service port valve, cap and retainer clip (4). The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the liquid line is disconnected. The A/C liquid line cannot be repaired and must be replaced if leaking or damaged. Rear DESCRIPTION The rear A/C liquid line (1) is the refrigerant line that carries refrigerant from the A/C condenser to the rear A/C evaporator. The rear A/C liquid line Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 7361 serviced in two sections and includes a tapping plate (4) that retains the A/C suction line (3) . Models equipped with the rear heating-A/C system include an extension tube (8) that connects the liquid line to the underbody line by use of a spring-lock type refrigerant line coupler (6) and a secondary retaining clip (7). NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The rear A/C liquid line has no serviceable parts except for the rubber O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C liquid line is disconnected. The rear A/C liquid line cannot be repaired and must be replaced if leaking or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 7362 Hose/Line HVAC: Description and Operation A/C Suction Line - Description Front DESCRIPTION The A/C suction line (9) is the refrigerant line that carries refrigerant from the A/C evaporator to the A/C compressor. The A/C suction line includes the low side service port (6) and is secured to the A/C expansion valve (7) by the liquid line tapping plate (8). On models equipped with the rear heating-A/C system, the A/C suction line also includes an extension tube that connects the suction line to the underbody lines . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C suction line has no serviceable parts except for the rubber O-ring seals, low-side service port valve and cap. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C suction line is disconnected. The A/C suction line cannot be repaired and must be replaced if leaking or damaged. Rear DESCRIPTION The rear A/C suction line (3) is the refrigerant line that carries refrigerant from the rear A/C evaporator to the A/C compressor. The rear A/c suction line is retained into the liquid line tapping block (4) by a plastic retainer . Models equipped with the rear heating-A/C system include an extension tube (5) that connects the suction line to the underbody line by use of a spring-lock type refrigerant line coupler (6) and a secondary retaining clip (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 7363 NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The rear A/C suction line has no serviceable parts except for the rubber O-ring seals. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the A/C suction line is disconnected. The rear A/C suction line cannot be repaired and must be replaced if leaking or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Description and Operation > A/C Discharge Line - Description > Page 7364 Hose/Line HVAC: Description and Operation A/C Underbody Lines - Description DESCRIPTION Models equipped with the rear heating-A/C system use metal lines (1) attached to the vehicle underbody (2) to carry refrigerant and engine coolant to/and from the rear A/C evaporator and heater core. The underbody A/C lines are connected to the front A/C suction and liquid lines by spring-lock type couplers and secondary retaining clips See: Coupler HVAC/Description and Operation/Refrigerant Line Coupler - Description and to the rear HVAC housing (3) by a tapping plate (4) and nut (5). The metal underbody heater lines have rubber hose ends that are connected to the front heater hoses and the rear HVAC housing by use of spring-clamp type heater hose clamps. The underbody lines are retained by plastic mounting brackets (6) and screws (7) and can be repaired (depending on the amount of damage) by using A/C Line Repair Tool Kit 8456A or equivalent See: Service and Repair/Procedures. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The underbody lines can only be removed by lifting the body off of the frame and have no serviceable parts except for the refrigerant line rubber O-ring seals and the mounting brackets. The O-ring seals used on the refrigerant line connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals must be replaced whenever the underbody refrigerant lines are disconnected. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures Hose/Line HVAC: Procedures UNDERBODY LINE REPAIR WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. WARNING: This procedure is intended for underbody line repair only. Use of the connector fittings and A/C Line Repair Tools 8456A on any other type of vehicle tubing may cause tube failure resulting in possible serious or fatal injury. 1. If repairing an underbody refrigerant line, recover the refrigerant from the refrigerant system See: Refrigerant/Service and Repair. 2. If repairing an underbody coolant line, drain the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 3. Disconnect and isolate the negative battery cable. 4. Raise and support the vehicle. 5. Remove the underbody mounting brackets as necessary to gain access to the underbody line(s) needing repair See: Removal and Replacement/A/C Underbody Lines - Removal. 6. Mark the cut location(s) on the underbody line(s) needing repair. Check the Tube Length chart for the minimum amount of straight tube required (dimension A) for proper connector fitting installation. 7. Using a small pipe cutter or another suitable tool, carefully cut the underbody line(s) needing repair at the location(s) previously marked. TUBE LENGTH Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7367 8. Size a replacement line, same size diameter and length as the portion of the line(s) removed. NOTE: A minimum of 28.5 mm (3/4 in) of the line end must be cleaned in order for the connector fitting to properly seal the repair area. 9. Clean the ends of the line(s) a minimum of 28.5 mm (3/4 in) (dimension A) using the Scotch-Bright (R) pad provided with A/C Line Repair Tools 8456A. Clean the line end(s) with a rotational motion around the line to avoid longitudinal scratches in the line. 10. Select the proper connector fitting (1) for the size of the underbody line being repaired. Refer to the Connector Fitting chart. 11. Apply one drop of Lokprep(R) sealing compound provided with A/C Line Repair Tools 8456A onto each line end (2). 12. Insert the line ends into the selected connector fitting and rotate the connector fitting a complete turn to evenly distribute the sealing compound. CONNECTOR FITTING Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7368 13. Select the proper size jaws (1) for the line being repaired from the A/C Line Repair Tools 8456A. Refer to the Jaw Size chart. 14. Assemble the jaws into Tool Body 8456-3 (2) (in Kit 8456A). a. For standard installation, install the jaws with the rubber gripping pads (3) facing outward. See the Tube Length chart. b. For reversed installation, remove the rubber gripping pads and install the jaws with the rubber gripping pad area facing inward. See the Tube Length chart. JAW SIZE NOTE: The connector fitting ends must be positioned into the counterbore of the jaws in order for the connector fitting to properly seal the repair area. 15. Install the connector fitting (1) and the line ends (4) into the counterbore of the jaws (5). 16. Hold Tool Body 8456-3 (2) with a 3/8 inch breaker bar and turn the forcing screw (3) clockwise. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7369 NOTE: The lines must be kept fully inserted into the connector fitting to obtain a leak free joint. 17. Turn the forcing screw (1) clockwise until both connector fitting collars (2) have bottomed out on the center shoulder of the connector (3). 18. Loosen the forcing screw and remove Tool Body 8456-3 (4) and the jaws (5) from the repaired line(s). 19. Install the underbody mounting brackets as necessary See: Removal and Replacement/A/C Underbody Lines - Installation. 20. Lower the vehicle. 21. Reconnect the negative battery cable. 22. If repairing an underbody coolant line, refill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 23. If repairing an underbody refrigerant line, evacuate and charge the refrigerant systemSee: Service and Repair/Refrigerant System Charge Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7370 Hose/Line HVAC: Removal and Replacement A/C Discharge Line - Removal 5.7L ENGINES WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: Typical A/C discharge line shown. 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 4. Disconnect the wire harness connector (6) from the A/C pressure transducer (5). 5. If required, remove the A/C pressure transducer from the A/C discharge line (1). 6. Remove the nut (7) that secures the A/C discharge line to the A/C condenser (2). 7. Disconnect the A/C discharge line from the A/C condenser and the retainer (3) located on the condenser fan shroud (4). 8. Remove the O-ring seal and gasket from the discharge line fitting and discard. 9. Install plugs in, or tape over, the discharge line fitting and condenser port. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7371 NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 10. If required, raise and support the vehicle. 11. Remove the nut (6) that secures the A/C discharge line (1) to the A/C compressor (5). CAUTION: On HEV models, a small quantity of refrigerant oil may be lost from the A/C compressor when the A/C discharge line is disconnected. Prior to removing the A/C discharge line from the A/C compressor, it very important to place a small clean container below the discharge line fitting to capture any refrigerant oil that may leak from the compressor discharge port. Always measure the amount of refrigerant oil lost and replace with the same amount of fresh clean ND-11 POE refrigerant oil prior to recharging the A/C system. Never use PAG oil in an HEV model or operate the A/C system with an incorrect amount of oil in the system. Failure to follow this caution may result in serious damage to the HEV A/C system. 12. Disconnect the A/C discharge line from the A/C compressor and remove and discard the O-ring seal and gasket. 13. Install plugs in, or tape over, the opened refrigerant line fitting and the compressor port. 14. Remove the A/C discharge line from the engine compartment. A/C Discharge Line - Installation 5.7L ENGINES CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: Always use ND-11 Polyester (POE) oil from Mopar(R) in Hybrid Electric Vehicle (HEV) models. Never use Polyalkylene Glycol (PAG) oil in an HEV model. See Refrigerant Oil for more information. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7372 NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 1. Position the A/C discharge line (1) into the engine compartment. 2. Remove the tape or plugs from the opened discharge line fitting and the compressor port. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Install the A/C discharge line onto the A/C compressor (5). 5. Install the nut (6) that secures the A/C discharge line to the A/C compressor. Tighten the nut to 23 Nm (17 ft. lbs.). NOTE: Typical A/C discharge line shown. 6. If required, lower the vehicle 7. Remove the tape or plugs from the opened discharge line fitting (1) and the condenser port (2). 8. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 9. Install the A/C discharge line to the A/C condenser and the retainer (3) located on the condenser fan shroud. 10. Install the nut (7) that secures the A/C discharge line to the A/C condenser. Tighten the nut to 22 Nm (16 ft. lbs.). 11. If removed, install the A/C pressure transducer (5) onto the A/C discharge line. 12. Connect the wire harness connector (6) to the A/C pressure transducer. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 13. On HEV models, reconnect the battery system using the service disconnect at the battery pack . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 14. On gasoline only models, reconnect the negative battery cable. 15. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7373 CAUTION: On HEV models, a small quantity of refrigerant oil may have been lost from the A/C compressor when the A/C discharge line was disconnected. Always replace the lost oil with the same amount of fresh clean ND-11 POE refrigerant oil prior to recharging the A/C system. Never use PAG oil in an HEV model or operate the A/C system with an incorrect amount of oil in the system. Failure to follow this caution may result in serious damage to the HEV A/C system. 16. Adjust the refrigerant oil level See: Specifications/Capacity Specifications/Refrigerant Oil Capacity. 17. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Front REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: The A/C liquid line is serviced in two sections. The front section connects between the A/C condenser and the receiver/drier. The rear section connects between the receiver/drier and the A/C expansion valve. On models equipped with the rear heating-A/C system, the rear section of the A/C liquid line also includes an extension tube that connects the liquid line to the underbody lines. FRONT SECTION 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 4. Remove the air cleaner housing and resonator (1) See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7374 5. Remove the bolt (1) that secures the front section of the A/C liquid line (2) to the receiver/drier (3). 6. Disconnect the front section of the A/C liquid line from the receiver/drier and remove and discard the O-ring seal. 7. Install plugs in, or tape over, the opened liquid line fitting and receiver/drier port. 8. Remove the nut (1) that secures the front section of the A/C liquid line (2) to the A/C condenser (3). 9. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket. 10. Install plugs in, or tape over, the opened liquid line fitting and condenser port. 11. Remove the front section of the A/C liquid line from the engine compartment. REAR SECTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7375 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 4. Remove the air cleaner housing and resonator (1) See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. 5. Remove the rear section of the A/C liquid line (2) from the plastic retainer (3) located on the right inner fender (4). 6. On HEV models, drain the coolant for the Traction Power Inverter Module (TPIM) (1) and remove the coolant recovery bottle See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/TPIM Coolant Recovery Container - Removal. 7. Remove the TPIM and mounting bracket (2) to gain access to the A/C liquid line See: Hybrid Drive Systems/Power Control System/Voltage Inverter/Service and Repair/Traction Power Inverter Module - Removal. 8. Remove the bolt (1) that secures the rear section of the A/C liquid line (2) to the receiver/drier (3). 9. Disconnect the rear section of the A/C liquid line from the receiver/drier and remove and discard the O-ring seal. 10. Install plugs in, or tape over the opened liquid line fitting and the receiver/drier port. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7376 11. Raise and support the vehicle. 12. Remove the right front wheelhouse splash shield. 13. Remove the plastic retainer (1) that secures the A/C suction line (2) to the liquid line tapping block (4). 14. Remove the nut (3) that secures the liquid line tapping block to the A/C expansion valve (5). 15. Disconnect the A/C suction line and the rear section of the A/C liquid line from the A/C expansion valve and remove and discard the O-ring seals and gaskets. 16. Install plugs in, or tape over the opened refrigerant line fittings and the expansion valve ports. 17. Separate the A/C suction line from the liquid line tapping block. 18. On models equipped with the rear heating-A/C system, disconnect the underbody liquid line from the liquid line tapping block See: Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Removal and See: A/C Liquid Line Removal. 19. Remove the rear section of the A/C liquid line from the engine compartment. Rear REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: The A/C liquid line is serviced in two sections. The front section connects between the A/C condenser and the receiver/drier. The rear section connects between the receiver/drier and the front A/C expansion valve. On models equipped with the rear heating-A/C system, the rear section of the A/C liquid line also includes an extension tube that connects the liquid line to the underbody lines. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7377 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 4. Disconnect the A/C liquid line (1) from the receiver/drier and the front A/C expansion valve See: A/C Liquid Line - Removal. 5. Remove the secondary retaining clip (7) from the refrigerant line coupler (6) on the liquid line extension tube (8) 6. Disconnect the underbody liquid line from the liquid line extension tube using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent) and remove and discard the O-ring seal See: Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Removal. 7. Install plugs in, or tape over the refrigerant line coupler and the underbody liquid line. 8. Remove the A/C liquid line from the engine compartment. Front INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: Always use ND-11 Polyester (POE) oil from Mopar(R) in Hybrid Electric Vehicle (HEV) models. Never use Polyalkylene Glycol (PAG) oil in an HEV model. See Refrigerant Oil for more information. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C liquid line is serviced in two sections. The front section connects between the A/C condenser and the receiver/drier. The rear section connects between the receiver/drier and the A/C expansion valve. On models equipped with the rear heating-A/C system, the rear section of the A/C liquid line also includes an extension tube that connects the liquid line to the underbody lines. FRONT SECTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7378 1. Position the front section of the A/C liquid line (2) into the engine compartment. 2. Remove the tape or plugs from the liquid line fitting and the condenser port. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the A/C liquid line to the A/C condenser (3). 5. Install the nut (1) that secures the A/C liquid line to the A/C condenser. Tighten the nut to 22 Nm (16 ft. lbs.). 6. Remove the tape or plugs from the liquid line fitting and the receiver/drier (3). 7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 8. Connect the front section of the A/C liquid line (2) to the receiver/drier. 9. Install the bolt (1) that secures the front section of the A/C liquid line to the receiver/drier. Tighten the bolt to 13.5 Nm (120 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7379 10. Install the air cleaner housing and resonator (1) See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 11. On HEV models, reconnect the battery system using the service disconnect at the battery pack . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 12. On gasoline only models, connect the negative battery cable. 13. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 14. Adjust the refrigerant oil level See: Specifications/Capacity Specifications/Refrigerant Oil Capacity. 15. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. REAR SECTION 1. Position the rear section of the A/C liquid line into the engine compartment. 2. Install the A/C suction line (2) into the liquid line tapping block (4). 3. Install the plastic retainer (1) that secures the A/C suction line to the liquid line tapping block. 4. Remove the tape or plugs from the suction and liquid line fittings and the A/C expansion valve (5). 5. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and a new gasket onto the A/C expansion valve. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 6. Connect the A/C suction line and the rear section of the A/C liquid line to the A/C expansion valve. 7. Install the nut (3) that secures the refrigerant line tapping block to the A/C expansion valve. Tighten the nut to 23 Nm (17 ft. lbs.). 8. On models equipped with the rear heating-A/C system, connect the underbody liquid line to the liquid line tapping block See: A/C Liquid Line Installation or See: Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Installation. 9. Install the right front wheelhouse splash shield. 10. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7380 11. Remove the tape or plugs from the liquid line fitting and the receiver/drier (3). 12. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 13. Connect the rear section of the A/C liquid line (2) to the receiver/drier. 14. Install the bolt (1) that secures the rear section of the A/C liquid line to the receiver/drier. Tighten the bolt to 11 Nm (97 in. lbs.). 15. On Hybrid Electric Vehicle (HEV) models, install the Traction Power Inverter Module (TPIM) (1) and mounting bracket (2) See: Hybrid Drive Systems/Power Control System/Voltage Inverter/Service and Repair/Traction Power Inverter Module - Installation. 16. Install the TPIM coolant recovery bottle See: Engine, Cooling and Exhaust/Cooling System/Coolant Reservoir/Service and Repair/TPIM Coolant Recovery Container - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7381 17. Install the rear section of the liquid line (2) into the plastic retainer (3) located on the right inner fender (4). 18. Install the air cleaner housing and resonator (1) See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 19. On HEV models, reconnect the battery system using the service disconnect at the battery pack . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 20. On gasoline only models, connect the negative battery cable. 21. On HEV models, refill the TPIM cooling system . See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 22. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 23. Adjust the refrigerant oil level See: Specifications/Capacity Specifications/Refrigerant Oil Capacity. 24. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Rear INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: Always use ND-11 Polyester (POE) oil from Mopar(R) in Hybrid Electric Vehicle (HEV) models. Never use Polyalkylene Glycol (PAG) oil in an HEV model. See Refrigerant Oil for more information. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C liquid line is serviced in two sections. The front section connects between the A/C condenser and the receiver/drier. The rear section connects between the receiver/drier and the front A/C expansion valve. On models equipped with the rear heating-A/C system, the rear section of the A/C liquid line also includes an extension tube that connects the liquid line to the underbody lines. 1. Install the A/C liquid line (1) to the receiver/drier and the front A/C expansion valve See: A/C Liquid Line - Installation 2. Remove the tape or plugs from the refrigerant line coupler (6) and the underbody liquid line. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the refrigerant line coupler. Use only the specified O-ring as it is Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7382 made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the underbody liquid line to liquid line extension tube (8) See: Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Installation. 5. Install the secondary retaining clip (7) onto the refrigerant line coupler. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 6. On HEV models, reconnect the battery system using the service disconnect at the battery pack . See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 7. On gasoline only models, reconnect the negative battery cable. 8. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 9. Adjust the refrigerant oil level See: Specifications/Capacity Specifications/Refrigerant Oil Capacity. 10. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Front 5.7L ENGINES WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: The A/C suction line on 5.7L engines is serviced in two sections. FRONT SECTION NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 4. Raise and support the vehicle. 5. Remove the nut (3) that secures the A/C suction line (2) to the A/C compressor (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7383 CAUTION: On HEV models, a small quantity of refrigerant oil may be lost from the A/C compressor when the A/C suction line is disconnected. Prior to removing the A/C suction line from the A/C compressor, it very important to place a small clean container below the suction line fitting to capture any refrigerant oil that may leak from the compressor suction port. Always measure the amount of refrigerant oil lost and replace with the same amount of fresh clean ND-11 POE refrigerant oil prior to recharging the A/C system. Never use PAG oil in an HEV model or operate the A/C system with an incorrect amount of oil in the system. Failure to follow this caution may result in serious damage to the HEV A/C system. 6. Disconnect the A/C suction line from the A/C compressor and remove and discard the O-ring seal and gasket. 7. Install plugs in, or tape over, the opened suction line fitting and the compressor port. 8. On HEV model, disengage the wire harness (1) from the suction line bracket (2) and remove the bolt that secures the bracket to the front of the engine. NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 9. Lower the vehicle. 10. Remove the air cleaner housing and resonator See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. 11. Remove the nut (1) that secures the front section of the A/C suction line (4) to the rear section of the A/C suction line (2). 12. On 5.7L gas only model, remove the nut (5) that secures the front section of the A/C suction line to the bracket (3) located at the front of the engine. 13. Remove the front section of the A/C suction line and remove and discard the O-ring seal and gasket. 14. Install plugs in, or tape over, the opened suction line fittings. REAR SECTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7384 NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 4. Remove the air cleaner housing and resonator See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal. 5. Remove the nut (1) that secures the front section of the A/C suction line (4) to the rear section of the A/C suction line (2). 6. Install plugs in, or tape over, the opened suction line fittings. 7. Raise and support the vehicle. 8. Remove the right front wheelhouse splash shield. 9. Remove the plastic retainer (1) that secures the rear section of the A/C suction line (2) to the liquid line tapping block (4). 10. Remove the nut (3) that secures the liquid line tapping block to the A/C expansion valve (5). 11. Disconnect the A/C suction and liquid lines from the A/C expansion valve and remove and discard the O-ring seals and gaskets. 12. Install plugs in, or tape over, the opened refrigerant line fittings and expansion valve ports. 13. Separate the A/C suction line from the liquid line tapping block. 14. On models equipped with the rear heating-A/C\ system, disconnect the underbody refrigerant line from the A/C suction line\ See: Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Removal and See: A/C Suction Line Removal. 15. Remove the rear section of the A/C suction line from the engine compartment. Rear REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7385 Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: The A/C suction line connects between the A/C evaporator and the A/C compressor. On models equipped with the rear heating-A/C system, the A/C suction line also includes an extension tube that connects the suction line to the underbody lines. 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 4. Disconnect the A/C suction line (3) from the A/C compressor and the front A/C expansion valve See: A/C Suction Line - Removal 5. Remove the secondary retaining clip (2) from the refrigerant line coupler (6) on the suction line extension tube (5) 6. Disconnect the underbody suction line from the suction line extension tube using the proper A/C line disconnect tool (Special Tool Kit 7193 or equivalent) and remove and discard the O-ring seal See: Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Removal. 7. Install plugs in, or tape over the refrigerant line coupler and the underbody suction line. 8. Remove the A/C suction line from the engine compartment. Front 5.7L ENGINE CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: Always use ND-11 Polyester (POE) oil from Mopar(R) in Hybrid Electric Vehicle (HEV) models. Never use Polyalkylene Glycol (PAG) oil in an HEV model. See Refrigerant Oil for more information. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant systemSee: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7386 NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C suction line on 5.7L engines is serviced in two sections. FRONT SECTION NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 1. Position the front section of the A/C suction line (4) into the engine compartment. 2. Remove the tape or plugs from the open suction line fittings. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the front section of the A/C suction line to the rear section of the A/C suction line (2) and install the retaining nut (1). Tighten the nut to 23 Nm (17 ft. lbs.). 5. On 5.7L gas only model, install the nut (5) that secures the front section of the A/C suction line to the bracket (3) located at the front of the engine. Tighten the nut securely. NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 6. Raise and support the vehicle. 7. Remove the tape or plugs from the open suction line fitting and the compressor port. 8. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 9. Install the A/C suction line (2) onto the A/C compressor (5). 10. Install the nut (3) that secures the A/C suction line to the A/C compressor. Tighten the nut to 23 Nm (17 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7387 11. On HEV model, install the suction line bracket (2) and retaining bolt and engage the wire harness (1) to the bracket. Tighten the bolt securely. 12. Lower the vehicle. 13. Install the air cleaner housing and resonator See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 14. On HEV models, reconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 15. On gasoline only models, reconnect the negative battery cable. 16. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. CAUTION: On HEV models, a small quantity of refrigerant oil may have been lost from the A/C compressor when the A/C suction line was disconnected. Always replace the lost oil with the same amount of fresh clean ND-11 POE refrigerant oil prior to recharging the A/C system. Never use PAG oil in an HEV model or operate the A/C system with an incorrect amount of oil in the system. Failure to follow this caution may result in serious damage to the HEV A/C system. 17. Adjust the refrigerant oil level See: Specifications/Capacity Specifications/Refrigerant Oil Capacity. 18. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. REAR SECTION 1. Position the rear section of the A/C suction line (2) into the engine compartment. 2. Install the A/C suction line into the liquid line tapping block (4). 3. Install the plastic retainer (1) that secures the A/C suction line to the liquid line tapping block. 4. Remove the tape or plugs from the suction and liquid line fittings and the A/C expansion valve (5). 5. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and a new gasket onto the suction and liquid line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7388 6. Connect the A/C suction line and A/C liquid line to the A/C expansion valve. 7. Install the nut (3) that secures the refrigerant line tapping block to the A/C expansion valve. Tighten the nut to 23 Nm (17 ft. lbs.). 8. On models equipped with the rear heating-A/C system, connect the underbody refrigerant line to the A/C suction lineSee: A/C Suction Line Installation and See: Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Installation. 9. Install the right front wheelhouse splash shield. NOTE: 5.7L gas only engine shown. 5.7L HEV engine similar. 10. Lower the vehicle. 11. Remove the tape or plugs from the open suction line fittings. 12. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the suction line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 13. Connect the front section of the A/C suction line (4) to the rear section of the A/C suction line (2) and install the retaining nut (1). Tighten the nut to 23 Nm (17 ft. lbs.). 14. Install the air cleaner housing and resonatorSee: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Installation. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 15. On HEV models, reconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 16. On gasoline only models, reconnect the negative battery cable. 17. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. CAUTION: On HEV models, a small quantity of refrigerant oil may have been lost from the A/C compressor when the A/C suction line was disconnected. Always replace the lost oil with the same amount of fresh clean ND-11 POE refrigerant oil prior to recharging the A/C system. Never use PAG oil in an HEV model or operate the A/C system with an incorrect amount of oil in the system. Failure to follow this caution may result in serious damage to the HEV A/C system. 18. Adjust the refrigerant oil level See: Specifications/Capacity Specifications/Refrigerant Oil Capacity. 19. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Rear INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: Always use ND-11 Polyester (POE) oil from Mopar(R) in Hybrid Electric Vehicle (HEV) models. Never use Polyalkylene Glycol (PAG) oil in an HEV model. See Refrigerant Oil for more information. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7389 hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. NOTE: The A/C suction line connects between the A/C evaporator and the A/C compressor. On models equipped with the rear heating-A/C system, the A/C suction line also includes an extension tube that connects the suction line to the underbody lines. 1. Install the A/C suction line (3) to the A/C compressor and the front A/C expansion valve See: A/C Suction Line - Installation. 2. Remove the tape or plugs from the refrigerant line coupler (6) and the underbody suction line. 3. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it onto the refrigerant line coupler. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 4. Connect the underbody suction line to the suction line extension tube (5) See: Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Installation. 5. Install the secondary retaining clip (2) onto the refrigerant line coupler. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 6. On HEV models, reconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 7. On gasoline only models, reconnect the negative battery cable. 8. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 9. Adjust the refrigerant oil level See: Specifications/Capacity Specifications/Refrigerant Oil Capacity. 10. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. A/C Underbody Lines - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7390 use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 4. Drain the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 5. Raise and support the vehicle. 6. Remove the right front wheelhouse splash shield. 7. Remove the secondary retaining clips (2 and 7) from the refrigerant line couplers (6) located on the suction line extension tube (5) and the liquid line extension tube (8). 8. Disconnect the underbody liquid and suction lines from the liquid line extension tube and the suction line extension tube using the proper A/C line disconnect tools (Special Tool Kit 7193 or equivalent) and remove and discard the O-ring seals See: Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Removal. 9. Install plugs in, or tape over the refrigerant line couplers and the underbody refrigerant lines. 10. Disconnect the underbody heater hoses from the front heater hoses. 11. Remove the nut (1) that secures the rear suction line (2) and the rear liquid line (3) to the rear evaporator line tapping plate that extends through the rear floor panel (4) behind the right rear wheel housing. 12. Disconnect the rear suction line and liquid line from the rear evaporator line tapping plate and remove and discard the O-ring seals. 13. Install plugs in, or tape over the opened refrigerant lines and tapping plate ports. 14. Disconnect the rear heater hoses (5) from the rear heater core tubes that extend through the rear floor panel behind the right rear wheel housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7391 15. Remove all body mount bolts on the passenger side of the vehicle and loosen the body mount bolts on the drivers side. 16. Place a jackstand at the front and rear of the vehicle on the passenger side so that the stands will safely support the body. 17. Remove the five screws (7) that secure the underbody lines (1) to the vehicle underbody (2). 18. Carefully lower the hoist until the right side of the body (supported by the stands) is approximately 76-101 mm (3-4 in.) above the frame. This will gain access to remove the underbody line assembly. 19. Remove the underbody line assembly from the underneath of the vehicle body. A/C Underbody Lines - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: Always use ND-11 Polyester (POE) oil from Mopar(R) in Hybrid Electric Vehicle (HEV) models. Never use Polyalkylene Glycol (PAG) oil in an HEV model. See Refrigerant Oil for more information. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7392 1. Position the underbody line assembly underneath the vehicle body. 2. Carefully raise the hoist until the frame and body mounts line up together. 3. Install the five screws that secure the underbody lines (1) to the vehicle underbody (2). 4. Install all body mount bolts to the passenger side of the vehicle. Tighten all passenger and driver side mount bolts securely. 5. Raise the hoist and remove the jack stands from under the vehicle. 6. Connect the rear heater hoses (5) to the rear heater core tubes that extend through the rear floor panel (4) behind the right rear wheel housing and install the heater hose clamps. 7. Remove the tape or plugs from fittings on the rear suction line (2) and the rear liquid line (3) and the rear evaporator extension line tapping plate ports. 8. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the rear suction and liquid line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 9. Connect the rear suction and liquid line fittings to the rear evaporator line tapping plate. 10. Install the nut (1) that secures the rear refrigerant lines to the rear evaporator line tapping plate. Tighten the nut to 23 Nm (17 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > Procedures > Page 7393 11. Connect the underbody heater hoses to the front heater hoses and install the heater hose clamps. 12. Remove the tape or plugs from the refrigerant line couplers (6) and the underbody refrigerant lines. 13. Lubricate a new rubber O-ring seal with clean refrigerant oil and install them onto the refrigerant line couplers. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 14. Connect the underbody liquid and suction lines to the liquid line extension tube (8) and the suction line extension tube (5) See: Coupler HVAC/Service and Repair/Refrigerant Line Coupler - Installation. 15. Install the secondary retaining clips (2 and 7) onto the refrigerant line couplers. 16. Install passenger side tires See: Maintenance/Wheels and Tires/Service and Repair/Removal and Replacement. 17. Install the right front wheelhouse splash shield. 18. Lower the vehicle. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 19. On HEV models, reconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 20. On gasoline only models, reconnect the negative battery cable. 21. Fill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 22. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 23. Adjust the refrigerant oil level See: Specifications/Capacity Specifications/Refrigerant Oil Capacity. 24. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Description and Operation > Front Housing Assembly HVAC: Description and Operation Front DESCRIPTION NOTE: Front single zone system shown. Front dual zone system similar. All models are equipped with a common HVAC housing (9) that combines A/C and heating capabilities into a single unit mounted within the passenger compartment. The heating-A/C system is a blend-air type system. In a blend-air system, blend-air doors (11) are used to control the amount of conditioned air that is allowed to flow through, or around the heater core (14). The temperature of the discharge air is varied by operating the blend door actuator (4), which moves the blend-air doors. In the available dual zone system, two blend door actuators and four blend-air doors are used to provide independent side-to-side temperature control of the discharge air. This design allows an almost immediate control of the output air temperature of the system. The electric actuators are connected to the vehicle electrical system by the HVAC wire harness (1). The mode door actuators (12) operate the mode-air doors (10 and 13), which direct the flow of the conditioned air out the various air outlets (depending on the mode selected). The recirculation door actuator (3), operates the recirculation-air door (2), which closes off the fresh air intake and recirculates the air already inside the vehicle. The blower motor (8) controls the velocity of air flowing through the HVAC housing by spinning the blower wheel (6) within the HVAC housing at the selected speed by use of the blower motor resistor block or power module (7) (depending on application). The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C evaporator (5) to cool and dehumidify the incoming air prior to blending it with the heated air. The front HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, recirculation-air door, mode-air doors, blend-air doors and linkage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Description and Operation > Front > Page 7398 Housing Assembly HVAC: Description and Operation Rear DESCRIPTION Models equipped with the rear heating-A/C system are equipped with a common rear heater-A/C housing (1) that combines A/C and heating capabilities into a single unit mounted within the passenger compartment. The rear heating-A/C system is a blend-air type system. A blend door actuator (7) operates the blend-air door which controls the amount of conditioned air that is allowed to flow through, or around, the heater core (6). The rear A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C expansion valve (5) and an A/C evaporator (4) to cool and dehumidify the incoming air prior to blending it with the heated air. A temperature control determines the discharge air temperature by operating the blend door actuator, which moves the blend-air door. This allows an almost immediate control of the output air temperature of the system. The mode door actuator (8) operates the mode-air door which directs the flow of the conditioned air out the upper or lower air outlets, depending on the discharge air temperature selected. Both electric actuators are connected to the vehicle electrical system by the rear heater-A/C wire harness. The rear blower motor (2) controls the velocity of air flowing through the rear heater-A/C housing by spinning the blower wheel at the selected speed by use of the rear blower motor resistor (3). The rear heater-A/C housing must be removed from the vehicle for service of the blower motor and disassembled for service of the A/C evaporator, heater core, mode-air door and blend-air door. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement Housing Assembly HVAC: Removal and Replacement Front HVAC Housing Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to follow the warnings and cautions may result in serious or fatal injury. WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: The front HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, recirculation-air door, mode-air doors, blend-air doors and linkage. 1. On Hybrid Electric Vehicles (HEV) models, disconnect the high voltage battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair 2. Disconnect the 12 volt battery system. 3. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 4. Drain the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 5. Remove the A/C expansion valve See: Expansion Valve/Service and Repair/A/C Expansion Valve - Removal. 6. Disconnect the heater hoses from the heater core tubes and install plugs or caps over the heater core tube openings. 7. Remove the four nuts (1) that secure the HVAC housing (2) to the engine compartment side of the dash panel (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7401 8. Remove the instrument panel from the passenger compartment See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 9. Disconnect the intermediate floor distribution duct from the front floor distribution duct. 10. Remove the two bolts (1) that secure the HVAC housing (2) to the passenger compartment side of the dash panel (3). 11. Pull the HVAC housing rearward so that the mounting studs and condensate drain tube clear the dash panel and remove the front HVAC housing from the passenger compartment. Front HVAC Housing Installation INSTALLATION 1. Position the HVAC housing (2) into the passenger compartment with the mounting studs and the condensate drain tube in their proper mounting locations in the dash panel (3). 2. Loosely install the two bolts (1) that secure the HVAC housing to the passenger compartment side of the dash panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7402 3. Install the four nuts (1) that secure the HVAC housing (2) to the engine compartment side of the dash panel (3). Tighten the nuts to 7 Nm (62 in. lbs.). 4. Tighten the two bolts that secure the HVAC housing to the passenger compartment side of the dash panel. Tighten the bolt(s) to 3 Nm (26 in. lbs.). 5. Connect the intermediate floor distribution duct to front floor distribution duct. 6. Install the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Installation. 7. Remove previously installed plugs or caps and connect the heater hoses to the heater core tubes. 8. Remove previously installed plugs or caps and install the A/C expansion valve and A/C liquid and suction lines See: Expansion Valve/Service and Repair/A/C Expansion Valve - Installation. 9. Connect the 12 volt battery system. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 10. On Hybrid Electric Vehicles (HEV) models, connect the high voltage battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 11. If the heater core is being replaced, flush the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 12. Refill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 13. Evacuate and charge the refrigerant system See: Service and Repair/Refrigerant System Charge. 14. Initiate the Actuator Calibration function using a scan tool . See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test Rear HVAC Housing Removal REMOVAL WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to follow the warnings and cautions may result in serious or fatal injury. NOTE: The rear heater-A/C housing must be removed from the vehicle for service of the blower motor and disassembled for service of the A/C evaporator, heater core, mode-air door and blend-air door. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7403 1. Disconnect and isolate the negative battery cable. 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Drain the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 4. Raise and support the vehicle. 5. Remove the nut (1) that secures the rear suction line (2) and the rear liquid line (3) to the rear evaporator extension line tapping plate that extends through the rear floor panel (4) behind the right rear wheel housing. 6. Disconnect the rear suction line and liquid line from the rear evaporator extension line tapping plate. 7. Remove the O-ring seals from the rear suction line and liquid line fittings and discard. 8. Install plugs in, or tape over the opened refrigerant lines and tapping plate ports. 9. Disconnect the rear heater hoses (5) from the rear heater core tubes that extend through the rear floor panel behind the right rear wheel housing. 10. Lower the vehicle. 11. Remove right rear quarter panel trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 12. Remove the rear distribution ducts from the rear HVAC housing (1) See: Air Duct/Service and Repair/Floor Distribution Duct - Removal. 13. Disconnect the body wire harness connector (2) from the rear heater-A/C wire harness connector (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7404 NOTE: Illustration shown with rear heater-A/C housing retaining bolts removed for clarity. NOTE: The three rear heater-A/C housing retaining bolts have a retaining washer to keep them attached to the rear housing. It is not necessary to completely remove the retaining bolts from the rear housing to remove the housing from the vehicle. 14. Completely loosen the three bolts (1) that secure the rear heater-A/C housing (2) to the rear interior quarter panel (3). 15. Remove the rear heater-A/C housing from the vehicle. Rear HVAC Housing Installation INSTALLATION 1. Position the rear heater-A/C housing (2) into the vehicle. 2. Install the three bolts (1) that secure the rear heater-A/C housing to the rear interior quarter panel (3). Tighten the bolts to 3 Nm (26 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7405 3. Connect the body wire harness connector (2) to the rear heater-A/C wire harness connector (3). 4. Install the rear distribution ducts to the rear heater-A/C housing (1) See: Air Duct/Service and Repair/Floor Distribution Duct - Installation. 5. Install the right rear quarter panel trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 6. Raise and support the vehicle. 7. Connect the rear heater hoses (5) to the rear heater core tubes that extend through the rear floor panel (4) behind the right rear wheel housing. 8. Remove the tape or plugs from fittings on the rear suction line (2) and the rear liquid line (3) and the rear evaporator extension line tapping plate ports. 9. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the rear suction and liquid line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 10. Connect the rear suction and liquid line fittings to the rear evaporator extension line tapping plate. 11. Install the nut (1) that secures the rear suction and liquid lines to the rear evaporator extension line tapping plate. Tighten the nut to 23 Nm (17 ft. lbs.). 12. Lower the vehicle. 13. Reconnect the negative battery cable. 14. If the heater core is being replaced, flush the cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 15. Fill the engine cooling system See: Engine, Cooling and Exhaust/Cooling System/Service and Repair. 16. Evacuate and charge the refrigerant system See: Service and Repair/Refrigerant System Charge. 17. Initiate the Actuator Calibration function using a scan tool . See: Testing and Inspection/Component Tests and General Diagnostics/HVAC System Test 18. Verify that the Actuator Calibration of the front A/C-heater control has passed. If an Actuator Calibration has not passed, correct any errors before proceeding. 19. Rotate the Rear Temperature Selector counter (1) clockwise to the Cold Position. Allow the Selector to remain in the Cold Position for 5 seconds. 20. Rotate the Rear Temperature Selector Clockwise to the Hot Position. Allow the Selector to remain in the Cold Position for 5 seconds. 21. Calibration is now complete. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7406 Housing Assembly HVAC: Overhaul Front HVAC Housing DISASSEMBLY NOTE: The front HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, recirculation-air door, mode-air doors, blend-air doors and linkage. NOTE: Gasoline model shown in illustrations. HEV model similar. 1. Remove the front HVAC housing (1) and place it on a workbenchSee: Removal and Replacement/Front HVAC Housing Removal. 2. Disconnect the HVAC wire harness (2) from the recirculation door actuator (3). 3. Remove the screws (4) that secure the air inlet housing (5) to the HVAC housing. 4. Remove the air inlet housing from the HVAC housing. 5. If required, remove the recirculation door actuator from the air inlet housingSee: Air Door/Air Door Actuator / Motor/Service and Repair/Recirculation Door Actuator - Removal. 6. Disconnect the HVAC wire harness (1) from the evaporator temperature sensor (2), blend door actuator (3) and the two mode door actuators (4). 7. Remove the evaporator temperature sensor from the top of the HVAC housing (5). 8. Remove the screws that secure the blend door actuator and the mode door actuators to the HVAC housing and remove the actuators. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7407 9. Remove the two actuator couplers (1) from the left end of the HVAC housing (2). 10. If equipped with front dual zone automatic temperature control (ATC) system, disconnect the HVAC wire harness (4) from driver side blend door actuator (2), remove the screws (1) that secure the blend door actuator and cover to the bottom of the HVAC housing (3) and remove the actuator. 11. Carefully remove the foam seal (1) from the flange on the HVAC housing (2). If the seal is deformed or damaged, it must be replaced. 12. Remove the screw (3) that secures the heater core tube retaining bracket (4) to the top of the HVAC housing. 13. Remove the heater core tube retaining bracket from the HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7408 14. Remove the two screws (1) that secure the HVAC housing retaining bracket (2) to the top of the HVAC housing (3). 15. Remove the HVAC housing retaining bracket from the HVAC housing. 16. Remove the two screws (4) that secure the heater core retaining bracket (5) to the top of the HVAC housing. 17. Carefully remove the heater core (6) from the HVAC housing. 18. Disconnect the HVAC wiring harness (1) from the blower motor (2). 19. Remove the blower motor from the HVAC housing (3). 20. Remove the evaporator temperature sensor See: Evaporator Temperature Sensor / Switch/Service and Repair/Front Evaporator Temperature Sensor - Removal. 21. Disconnect the HVAC wiring harness (1) from the blower motor resistor or power module (2), depending on application. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7409 22. If necessary, remove the blower motor resistor or power module, depending on application or See: Control Module HVAC/Service and Repair/Front Blower Motor Power Module - Removal. 23. Remove the HVAC wiring harness from the HVAC housing (3). 24. Remove the screws (4) that secure the two halves of the HVAC housing together. 25. Separate the two halves of the HVAC housing. 26. If necessary, remove the mode-air doors from the upper half of the HVAC housing. 27. Carefully lift the A/C evaporator (1) and insulator (3) out of the top of the HVAC housing (2). NOTE: Front single zone system shown. Front dual zone system similar. 28. Remove the blend-air doors and linkage (1), mode-air door (2), baffle (3) and the duct plate (4) from the lower half of the HVAC housing (6). 29. If necessary, remove the floor distribution duct (5) from the HVAC housing See: Air Duct/Service and Repair/Floor Distribution Duct - Removal. Rear HVAC Housing DISASSEMBLY NOTE: The rear heater-A/C housing must be removed from the vehicle for service of the blower motor and disassembled for service of the A/C evaporator, heater core, mode-air door and blend-air door. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7410 1. Remove the rear heater-A/C housing (1) and place it on a workbench See: Removal and Replacement/Front HVAC Housing Removal. 2. Disconnect the rear heater-A/C wire harness (3) from the rear blower motor resistor (4) and the rear blower motor (2). 3. Remove the rear blower motor resistor . 4. Remove the rear blower motor . 5. Disconnect the rear heater-A/C wire harness (3) from rear blend door actuator (5) and mode door actuator (1). 6. Disengage the rear heater-A/C wire harness from two retaining tabs (2 and 4) located on the top of the rear heater-A/C housing (6) and remove the wire harness. 7. Remove the rear blend door actuator and mode door actuator See: Air Door/Air Door Actuator / Motor/Service and Repair/Blend Door Actuator Removal and See: Air Door/Air Door Actuator / Motor/Service and Repair/Mode Door Actuator Removal. NOTE: If the foam seal for the flange is deformed or damaged, the seal be replaced. 8. Carefully remove the foam seal (3) from the rear heater core tube and evaporator line flange (2). 9. Remove the screw (4) that secures the rear heater core tube and evaporator line flange to the outboard side of the rear heater-A/C housing (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7411 10. Disengage the retaining tab (1) that secures the rear heater core tube and evaporator line flange to the rear heater-A/C housing and remove the flange. 11. Remove the screw (3) that secures the rear heater core retaining bracket (4) to the rear heater-A/C housing (1) and remove the bracket. NOTE: If a foam seal around the heater core is deformed or damaged, the seal must be replaced. 12. Carefully pull the rear heater core (2) out of the inboard side of the rear heater-A/C housing. 13. Remove the two bolts (1) that secure the rear evaporator extension lines (3) and the rear A/C expansion valve (2) to the rear evaporator tapping block (4). 14. Disconnect the rear evaporator extension lines from the rear A/C expansion valve (2) and remove the lines from the rear heater-A/C housing. 15. Disconnect the rear A/C expansion valve from the rear evaporator tapping block. 16. Remove and discard the O-ring seals and install plugs in, or tape over the opened extension line fittings and expansion valve and evaporator ports. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7412 17. Remove the twenty screws (3) that secure the two halves of the rear heater-A/C housing (1 and 2) together. 18. Separate the two halves of the rear heater-A/C housing from each other. NOTE: If the insulator around the A/C evaporator or evaporator tubes is deformed or damaged, the insulator must be replaced. 19. Carefully remove the rear A/C evaporator (1) out of the outboard half of the rear heater-A/C housing (3). NOTE: If the rubber seal is deformed or damaged, the seal must be replaced. 20. Remove the rubber seal (2) from the rear heater-A/C housing. NOTE: If a foam seal on an air door is deformed or damaged, the air door must be replaced. 21. Disengage the blend-air door (1) and the mode-air door (2) from the actuator couplers located on the inboard side of the rear heater-A/C housing (3) and remove the air doors. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7413 NOTE: Blend door actuator coupler shown. Mode door coupler similar. 22. Disengage the retaining tabs that secure each actuator coupler (1) to the inside of the rear heater-A/C housing (2) and remove the actuator couplers from the housing. Front HVAC Housing ASSEMBLY CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Gasoline model shown in illustrations. HEV model similar. NOTE: Front single zone system shown. Front dual zone system similar. 1. If removed, install the floor distribution duct (5) to the HVAC housing (6)See: Air Duct/Service and Repair/Floor Distribution Duct - Installation. 2. Install the blend-air doors and linkage (1), mode-air door (2), baffle (3) and the duct plate (4) into the lower half of the HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7414 3. Install the A/C evaporator (1) into the lower half of the HVAC housing (2). Make sure that the evaporator drain is clean and unrestricted and that the evaporator insulator (3) is properly installed. 4. If removed, install the mode-air doors into the upper half of the HVAC housing (2). 5. Align the ends of the blend-air door pivot shafts (1) to the openings in the upper half of the HVAC housing and install the upper housing half to the lower housing half. 6. Install the screws (4) that secure the two halves of the HVAC housing (3) together. Tighten the screws to 2.2 Nm (20 in lbs.). 7. Install the HVAC wiring harness (1). Make sure the harness is routed through all wiring retainers. 8. If removed, install the blower motor resistor or power module (2), depending on application. 9. Connect the HVAC wire harness to the blower motor resistor or power module, depending on application. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7415 10. Install the blower motor (2) to the HVAC housing (3) . 11. Connect the HVAC wire harness (1) to the blower motor. 12. Carefully install the heater core (6) into the top of the HVAC housing (3). Make sure that the heater core insulator is properly positioned. 13. Install the two screws (4) that secure the heater core retaining bracket (5) to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 14. Install the HVAC housing bracket (2) to the top of HVAC housing. 15. Install the two screws (1) that secure the HVAC housing bracket to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.). 16. Install the heater core tube retaining bracket (4) to the top of the HVAC housing (2). 17. Install the screw (3) that secures the heater core tube retaining bracket to the HVAC housing. Tighten the screw to 2.2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7416 18. Install the foam seal (1) to the flange on the HVAC housing. 19. If equipped with front dual zone automatic temperature control (ATC) system, install the driver side blend door actuator (2), cover and retaining screws (1) onto the bottom of the HVAC housing (3) and connect the HVAC wire harness (4) See: Air Door/Air Door Actuator / Motor/Service and Repair/Blend Door Actuator - Installation. 20. Align the two actuator couplers (1) with the mode-air door pivot shafts and install the couplers into the left side of the HVAC housing. Be sure to install the couplers with the coupler arm located between the two stop tabs on the HVAC housing. 21. Install the blend door actuator (3) and the mode door actuators (4) and retaining screws onto the HVAC housing (5) See: Air Door/Air Door Actuator / Motor/Service and Repair/Blend Door Actuator - Installation and See: Air Door/Air Door Actuator / Motor/Service and Repair/Mode Door Actuator - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7417 22. Install the evaporator temperature sensor (2) into the top of the HVAC housing. 23. Connect the HVAC wire harness (1) to the evaporator temperature sensor, blend door actuator and the mode door actuators. 24. If removed, install the recirculation door actuator (3) to the air inlet housing (5). 25. Install the air inlet housing onto the top of the HVAC housing (1). 26. Install the screws (4) that secure the air inlet housing to the HVAC housing. Make sure the HVAC wire harness retainer is properly installed. 27. Connect the HVAC wire harness to the recirculation door actuator (3). 28. Install the HVAC housing See: Removal and Replacement/Front HVAC Housing Installation. 29. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Rear HVAC Housing ASSEMBLY CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: If the rear A/C evaporator is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals could result in a refrigerant system leak. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7418 NOTE: Blend door actuator coupler shown. Mode door coupler similar. 1. Install the two actuator couplers (1) into the rear heater-A/C housing. Be sure to install the couplers with the coupler arm (3) located between the two stop tabs (4) on the rear heater-A/C housing. NOTE: If a foam seal on an air door is deformed or damaged, the air door must be replaced. 2. Install the blend-air door (1) and the mode-air door (2) the rear heater-A/C housing (3). Align the notch in the air doors with the coupler and fully engage the door to the coupler. NOTE: If the insulator around the A/C evaporator or evaporator tubes is deformed or damaged, the insulator must be replaced. 3. Carefully install the rear A/C evaporator (1) into the outboard half of the rear heater-A/C housing (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7419 NOTE: If the rubber seal is deformed or damaged, the seal must be replaced. 4. Install the rubber seal (2) into the groove on the rear heater-A/C housing. 5. Align the pivot shafts of the air doors located in the inboard half on the rear heater-A/C housing (1) to the openings located in outboard half of the rear heater-A/C housing (2) and install the two halves of the rear housing together. 6. Install the twenty screws (3) that secure the two halves of the rear heater-A/C housing together. Tighten the screws to 2 Nm (17 in. lbs.). 7. Remove the tape or plugs from the rear evaporator tube and extension line fittings and all rear expansion valve ports. 8. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto rear evaporator tube and extension line fittings. Use only the specified O-rings as they are made of a special material for the R-134a refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 9. Install the rear A/C expansion valve (2) onto the rear A/C evaporator tube tapping block (4). 10. Connect the rear evaporator extension lines (3) to the rear A/C expansion valve and install the two retaining bolts (1). Tighten the bolts to 11 Nm (97 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7420 NOTE: If a foam seal on the rear heater core is deformed or damaged, the seal must be replaced. 11. Install the rear heater core (2) into the inboard side of the rear heater-A/C housing (1). Make sure that the foam seals around the heater core are properly installed. 12. Install the rear heater core retaining bracket (4). 13. Install the screw (3) that secures the rear heater core retaining bracket to the rear heater-A/C housing. Tighten the screw to 2 Nm (17 in. lbs.). 14. Position the rear heater core tube and evaporator line flange (2) to the outboard side of the rear heater-A/C housing (5) and engage the retaining tab (1). Make sure the tab is fully engaged to the housing. 15. Install the screw (4) that secures the rear heater core tube and evaporator line flange to the inboard side of the rear heater-A/C housing. Tighten the screw to 2 Nm (17 in. lbs.). NOTE: If the foam seal for the flange is deformed or damaged, the seal be replaced. 16. Carefully install the foam seal (3) onto the rear heater core tube and evaporator line flange. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Removal and Replacement > Page 7421 17. Install the blend door actuator (5) and the mode door actuator (1) onto the rear heater-A/C housing (6) See: Air Door/Air Door Actuator / Motor/Service and Repair/Blend Door Actuator - Installation and See: Air Door/Air Door Actuator / Motor/Service and Repair/Mode Door Actuator - Installation. 18. Position the rear heater-A/C wire harness (3) to the top of the rear heater-A/C housing and engage the wiring harness to the two retaining tabs (2 and 4). Make sure the harness is fully engaged to the housing. 19. Disconnect the rear heater-A/C wire harness to rear blend door actuator and mode door actuator. 20. Install the rear blower motor resistor (4) . 21. Install the rear blower motor (2) . 22. Connect the rear heater-A/C wire harness (3) to the rear blower motor and the rear blower motor resistor. 23. Install the rear heater-A/C housing (1) See: Removal and Replacement/Front HVAC Housing Installation. 24. If the rear A/C evaporator is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Humidity Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Humidity Sensor > Component Information > Locations > Page 7425 Humidity Sensor: Diagrams Connector - (MIRROR JUMPER) 4 WAY SENSOR-HUMIDITY - (MIRROR JUMPER) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Humidity Sensor > Component Information > Description and Operation > Humidity Sensor - Description Humidity Sensor: Description and Operation Humidity Sensor - Description DESCRIPTION A humidity sensor (1) is used on HEV models to detect humidity levels inside the vehicle to optimize the dehumidifying effect of the A/C system, which reduces electronic air conditioning (EAC) power consumption. The humidity sensor attaches to the interior rear view mirror base (2) and is connected to the vehicle electrical system by a wire lead and connector of the mirror wire harness (3). The humidity sensor can be serviced from the interior rear view mirror without the use of any special tools. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Humidity Sensor > Component Information > Description and Operation > Humidity Sensor - Description > Page 7428 Humidity Sensor: Description and Operation Humidity Sensor - Operation OPERATION The humidity sensor detects humidity, dew point, windshield temperature and infrared sensor data and sends this information to the Hybrid Gateway Module (HGM) via a Local Interconnect Network (LIN) bus connection. The HGM then sends the message via the Controller Area Network (CAN) C bus to the Front Control Module (FCM), which ports the message to the A/C-heater control over the CAN B bus. If the humidity sensor message is not received by the A/C-heater control, the evaporator logic will be disabled, the evaporator target will be set to 3.3° C (38° F) and a Diagnostic Trouble Code (DTC) will set. The information the A/C-heater control receives from the humidity sensor can be viewed using a scan tool. The humidity sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The humidity sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Humidity Sensor > Component Information > Service and Repair > Humidity Sensor - Removal Humidity Sensor: Service and Repair Humidity Sensor - Removal REMOVAL 1. Disconnect and isolate the negative battery cable 2. Remove the inside rear view mirror from the front glass See: Body and Frame/Mirrors/Service and Repair/Interior Rearview Mirror - Removal 3. Disconnect the retaining tabs that secure the humidity sensor (1) to the mirror base (2) and slide the sensor off the base. 4. Disconnect the wire harness connector (3) from the humidity sensor and remove the sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Humidity Sensor > Component Information > Service and Repair > Humidity Sensor - Removal > Page 7431 Humidity Sensor: Service and Repair Humidity Sensor - Installation INSTALLATION 1. Connect the mirror wire harness (3) to the humidity sensor (1). 2. Position the humidity sensor onto the rear view mirror base (2) and engage the retaining tabs. Make sure the retaining tabs are fully engaged. 3. Install the interior rear view mirror See: Body and Frame/Mirrors/Service and Repair/Interior Rearview Mirror - Installation. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Front A/C Receiver Drier - Description Receiver Dryer: Description and Operation Front A/C Receiver Drier - Description DESCRIPTION The receiver/drier (1) is mounted in a bracket (2) secured to the right front frame rail (4) in the engine compartment. The receiver/drier is connected between the front section of the liquid line (3) and the rear section of the liquid line (5) between the condenser outlet and the evaporator inlet. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Front A/C Receiver Drier - Description > Page 7436 Receiver Dryer: Description and Operation Front A/C Receiver Drier - Operation OPERATION The A/C receiver/drier performs a filtering action to prevent foreign material in the refrigerant from contaminating the A/C expansion valve. Refrigerant enters the A/C receiver/drier as a high-pressure, low temperature liquid. Desiccant inside the A/C receiver/drier absorbs any moisture which may have entered and become trapped within the refrigerant system. In addition, during periods of high demand operation of the A/C system, the A/C receiver/drier acts as a reservoir to store surplus refrigerant. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. The A/C receiver/drier has no serviceable parts except for the O-ring seals, gaskets and the high side service port valve and cap. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever the A/C receiver/drier is removed. The A/C receiver/drier cannot be repaired and must be replaced if leaking or damaged, or if an internal failure of the A/C compressor has occurred. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Front A/C Receiver Drier - Removal Receiver Dryer: Service and Repair Front A/C Receiver Drier - Removal REMOVAL WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety procedures. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down. Failure to follow these instructions may result in possible serious or fatal injury See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service Precautions WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in possible serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. 1. On HEV models, disconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 2. On gasoline only engine models, disconnect and isolate the negative battery cable. 3. Remove the front and the rear sections of the liquid line (1 and 4) from the receiver/drier (2) See: Hose/Line HVAC/Service and Repair/Removal and Replacement/A/C Liquid Line - Removal. 4. Remove the bolt (3) that secures the receiver/drier and bracket to the right front frame rail (5). 5. Remove the receiver/drier from the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Front A/C Receiver Drier - Removal > Page 7439 Receiver Dryer: Service and Repair Front A/C Receiver Drier - Installation INSTALLATION CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage. CAUTION: The A/C receiver/drier must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C receiver/drier can cause serious A/C compressor damage. CAUTION: Always use ND-11 Polyester (POE) oil from Mopar(R) in Hybrid Electric Vehicle (HEV) models. Never use Polyalkylene Glycol (PAG) oil in an HEV model. See Refrigerant Oil for more information. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity . NOTE: If only the A/C receiver/drier is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only the refrigerant oil of the type recommended for the A/C compressor in the vehicle. NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is disconnected. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak. 1. Position the receiver/drier and bracket (2) into the engine compartment. 2. Install the bolt (3) that secures the receiver/drier to the right front frame rail (5). Tighten the bolts to 9 Nm (80 in. lbs.). 3. Install the front and rear sections of the liquid line (1 and 4) to the receiver/drier See: Hose/Line HVAC/Service and Repair/Removal and Replacement/A/C Liquid Line - Installation. WARNING: Always follow vehicle service procedures to properly connect batteries on an HEV model. Serious or fatal injury may result from improper service procedures. 4. On HEV models, reconnect the battery system using the service disconnect at the battery pack See: Hybrid Drive Systems/Battery System, Hybrid Drive/Service and Repair. 5. On gasoline only models, reconnect the negative battery cable. 6. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 7. If the A/C receiver/drier is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system See: Specifications/Capacity Specifications/Refrigerant Oil Capacity. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Front A/C Receiver Drier - Removal > Page 7440 8. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications REFRIGERANT CHARGE CAPACITY REFRIGERANT CHARGE CAPACITY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 7445 Refrigerant: Fluid Type Specifications Fluid type.............................................................................................................................................. .........................................................................R-134a Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Description and Operation > A/C Refrigerant Refrigerant: Description and Operation A/C Refrigerant A/C REFRIGERANT The refrigerant used in this air conditioning system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone depleting chlorine. R-134a refrigerant is a nontoxic, nonflammable, clear and colorless liquefied gas. CAUTION: R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure. The A/C refrigerant system is filled-for-life at the factory and requires no regular maintenance. Although not required at specific intervals, the charge level should be checked if system performance deteriorates or if a noise or leak is suspected See: Testing and Inspection/Component Tests and General Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Description and Operation > A/C Refrigerant > Page 7448 Refrigerant: Description and Operation Refrigerant - Description DESCRIPTION The refrigerant used in this A/C system is a HydroFluoroCarbon (HFC), type R-134a. Unlike R-12, which is a ChloroFluoroCarbon (CFC), R-134a refrigerant does not contain ozone-depleting chlorine. R-134a refrigerant is a non-toxic, non-flammable, clear, and colorless liquefied gas. Even though R-134a does not contain chlorine, it must be reclaimed and recycled just like CFC-type refrigerants. This is because R-134a is a greenhouse gas and can contribute to global warming. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Description and Operation > A/C Refrigerant > Page 7449 Refrigerant: Description and Operation Refrigerant - Operation OPERATION R-134a refrigerant is not compatible with R-12 refrigerant in an A/C system. Even a small amount of R-12 refrigerant added to an R-134a refrigerant system will cause A/C compressor failure, refrigerant oil sludge or poor A/C system performance. In addition, the polyalkylene glycol (PAG) synthetic refrigerant oils used in an R-134a refrigerant system are not compatible with the mineral-based refrigerant oils used in an R-12 refrigerant system. R-134a refrigerant system service ports, service tool couplers and refrigerant dispensing bottles have all been designed with unique fittings to ensure that an R-134a refrigerant system is not accidentally contaminated with the wrong refrigerant (R-12). There are also labels posted in the engine compartment of the vehicle and on the A/C compressor to identify that the A/C system is equipped with R-134a refrigerant. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery Refrigerant: Service and Repair Refrigerant System - Recovery REFRIGERANT SYSTEM RECOVERY WARNING: Review safety precautions and warnings before performing this procedure See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. NOTE: If equipped with the rear heating-A/C system, use a heat gun to warm the underbody refrigerant lines to help remove any trapped refrigerant from the rear A/C system. When servicing the A/C system, an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 must be used (1). Per SAE standard J2788, refrigerant recovery stations must recover 95% of the refrigerant system within 30 minutes at 21.1° C (70° F) and be able to measure the amount of refrigerant removed from the system to an accuracy of 28 grams (1 oz.). See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 7452 Refrigerant: Service and Repair Refrigerant System - Evacuate REFRIGERANT SYSTEM EVACUATE NOTE: Special effort must be used to prevent moisture from entering the A/C system oil. Moisture in the oil is very difficult to remove and will cause a reliability problem with the compressor. If a compressor designed to use R-134a refrigerant is left open to the atmosphere for an extended period of time. It is recommended that the refrigerant oil be drained and replaced with new oil or a new A/C compressor be used. This will eliminate the possibility of contaminating the refrigerant system. If the refrigerant system has been open to the atmosphere, it must be evacuated before the system can be filled. Moisture and air mixed with the refrigerant will raise the compressor head pressure above acceptable operating levels. This will reduce the performance of the A/C system and damage the A/C compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system: NOTE: When connecting the service equipment coupling to the line fitting, verify that the valve of the coupling is fully closed. This will reduce the amount of effort required to make the connection. 1. Recover the refrigerant system See: Service and Repair/Refrigerant System Recovery. 2. Connect a suitable charging station, refrigerant recovery machine or a manifold gauge set with vacuum pump and refrigerant recovery equipment See: Service and Repair/Refrigerant System Recovery. 3. Open the suction and discharge valves and start the vacuum pump. The vacuum pump should run a minimum of 45 minutes prior to charge to eliminate all moisture in system. When the suction gauge reads -88 kPa (-26 in. Hg) vacuum or greater for 30 minutes, close all valves and turn off vacuum pump. If the system fails to reach specified vacuum, the refrigerant system likely has a leak that must be corrected. If the refrigerant system maintains specified vacuum for at least 30 minutes, start the vacuum pump, open the suction and discharge valves. Then allow the system to evacuate an additional 10 minutes. 4. Close all valves. Turn off and disconnect the vacuum pump. 5. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Service and Repair > Refrigerant System - Recovery > Page 7453 Refrigerant: Service and Repair Refrigerant System - Charge REFRIGERANT SYSTEM CHARGE WARNING: Review safety precautions and warnings before performing this procedure See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow these instructions may result in serious or fatal injury. NOTE: A/C system refrigerant capacity can be found on the HVAC Specification Label, located in the engine compartment. After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system See: Service and Repair/Refrigerant System Charge. Use an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 when charging the A/C system. Per SAE standard J2788, refrigerant recovery stations must charge the system to an accuracy of 14 grams (0.5 oz.). See the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment. CHARGING PROCEDURE CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. CAUTION: A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. See the equipment manufacturer instructions for more information. NOTE: The Underhood HVAC Specification Label contains the refrigerant fill capacity of the vehicle being serviced. 1. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 2. Connect a manifold gauge set or an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2788 to the refrigerant system. 3. Measure the proper amount of refrigerant and heat it to 52° C (125° F) with the charging station See: Specifications/Capacity Specifications/Refrigerant Charge Capacity. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment. 4. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system. 5. When the transfer of refrigerant has stopped, close both the suction and discharge valves. 6. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is operating and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). If the A/C compressor does not operate, test the compressor control circuits and repair as required. 7. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system. WARNING: Take care not to open the discharge (high pressure) valve at this time. Failure to follow this warning could result in possible serious or fatal injury. 8. Disconnect the charging station and manifold gauge set from the refrigerant system service ports. 9. Reinstall the caps onto the refrigerant system service ports. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITY When an A/C system is assembled at the factory, all components except the A/C compressor are refrigerant oil free. After the refrigerant system has been charged and operated, the refrigerant oil in the A/C compressor is dispersed throughout the refrigerant system. The A/C receiver/drier, A/C evaporator, A/C condenser and the A/C compressor will each retain a significant amount of the needed refrigerant oil. It is important to have the correct amount of refrigerant oil in the A/C system. This ensures proper lubrication of the A/C compressor. Too little oil will result in damage to the A/C compressor, while too much oil will reduce the cooling capacity of the A/C system and consequently result in higher discharge air temperatures. CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. CAUTION: ND-11 Polyester (POE) oil is used in the Denso ES34 A/C compressor found on HEV models. Never use PAG oil in an HEV model or operate the A/C system with an incorrect amount of oil in the system. Failure to follow this caution may result in serious damage to the HEV A/C system. CAUTION: ND-8 PAG oil is used in the Denso 10SR17 and 10SRE20 A/C compressors found on gasoline engine models. Only refrigerant oil of the same type should be used to service these A/C systems. Do not use any other refrigerant oil. Failure to follow this caution may result in serious damage to the A/C system. CAUTION: A/C refrigerant oil containers should be kept tightly capped until ready for use and then tightly capped after use to prevent contamination from moisture and dirt. Refrigerant oil quickly absorbs moisture it comes in contact with, therefore, special effort must be used to keep all A/C system components moisture-free. Moisture in refrigerant oil is very difficult to remove and will cause a reliability problem with the A/C compressor. NOTE: Most reclaim/recycling equipment will measure the lubricant being removed during recovery. This amount of lubricant should be added back into the system. Refer to the reclaim/recycling equipment manufacturers instructions. It will not be necessary to check the oil level in the A/C compressor or to add oil, unless there has been an oil loss. An oil loss may occur due to a rupture or leak from a refrigerant line, a connector fitting, a component, or a component seal. If a leak occurs, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system after the repair has been made. Refrigerant oil loss will be evident at the leak point by the presence of a wet, shiny surface around the leak. Refrigerant oil must be added when an A/C condenser, A/C receiver/drier or A/C evaporator is replaced (see Refrigerant Oil Capacities chart). The refrigerant oil level in a new A/C compressor must first be adjusted prior to compressor installation (see Compressor Oil Drain Procedure). REFRIGERANT OIL CAPACITIES COMPRESSOR OIL DRAIN PROCEDURE CAUTION: Be certain to adjust the refrigerant system oil level when replacing an A/C compressor. Failure to properly drain and measure the refrigerant oil from the A/C compressor can prevent the A/C system from operating as designed and cause serious compressor damage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7458 The A/C compressor is filled with refrigerant oil from the factory. Use the following procedure to drain and measure refrigerant oil from the A/C compressor. 1. Drain all of the refrigerant oil from the original A/C compressor in the vehicle into a clean measured container. 2. Drain all of the refrigerant oil from the new A/C compressor into a clean measured container. CAUTION: Use only clean refrigerant oil of the type recommended for the A/C compressor in the vehicle. 3. Refill the new A/C compressor with the same amount and type of refrigerant oil that was drained out of the original compressor. 4. Install the new A/C compressor onto the engine See: Compressor HVAC/Service and Repair/A/C Compressor - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7459 Refrigerant Oil: Fluid Type Specifications Gas Type...................................................................................................................................................... ..................................................................ND-8 PAG HEV Type...................................................................................................................................................... .................................................................ND-11 POE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Refrigerant Oil - Description Refrigerant Oil: Description and Operation Refrigerant Oil - Description Gas Models GAS MODELS The refrigerant oil used in the R-134a refrigerant system on models equipped with 3.7L, 4.7L and 5.7L gasoline engine, is a synthetic-based, polyalkylene glycol (PAG), wax free lubricant. Mineral based R-12 refrigerant oils are not compatible with PAG oils and should never be introduced to an R-134a refrigerant system. There are different PAG oils available. Each PAG oil contains a different additive package. A/C compressors in 3.7L, 4.7L and 5.7L gas engine models are designed to use ND-8 refrigerant oil. Use only this type of refrigerant oil. HEV Models HEV MODELS CAUTION: Polyalkylene Glycol (PAG) oil can contaminate the refrigerant system of a Hybrid Electric Vehicle (HEV) and lead to A/C system damage and failure. If the refrigerant recovery/recycling and charging equipment was last used on a non-HEV model, flush the hoses of the equipment with a solvent approved by the equipment manufacturer before using the equipment on an HEV model, or use refrigerant recovery/recycling and charging equipment designated only for HEV models by your service facility. See the operating instructions supplied by the equipment manufacturer for proper use and care of the refrigerant recovery/recycling and charging equipment. The refrigerant oil used in the R-134a refrigerant system on HEV models is a synthetic Polyester (POE) oil. Never use mineral based R-12 refrigerant oils or synthetic based PAG oils in HEV refrigerant system. There are different POE oil types and grades. Always use ND-11 POE refrigerant oil 68043289AA from Mopar(R) in an HEV model. Use of an incorrect refrigerant oil may create a compatibility problem and lead to A/C system failure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Description and Operation > Refrigerant Oil - Description > Page 7462 Refrigerant Oil: Description and Operation Refrigerant Oil - Operation OPERATION After performing any refrigerant recovery or recycling operation, always replenish the refrigerant system with the same amount of the recommended refrigerant oil as was removed. Too little refrigerant oil can cause A/C compressor damage, and too much can reduce A/C system performance. PAG refrigerant oil is more hygroscopic than mineral oil, and will absorb any moisture it comes into contact with, even moisture in the air. The PAG oil container should always be kept tightly capped until it is ready to be used. After use, recap the oil container immediately to prevent moisture contamination. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7466 Refrigerant Pressure Sensor / Switch: Diagrams Connector - (HEADLAMP AND DASH) 4 WAY TRANSDUCER-A/C PRESSURE - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Front A/C Pressure Transducer - Description Refrigerant Pressure Sensor / Switch: Description and Operation Front A/C Pressure Transducer Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Front A/C Pressure Transducer - Description > Page 7469 Refrigerant Pressure Sensor / Switch: Description and Operation Front A/C Pressure Transducer Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the discharge line. The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. A Schrader-type valve in the discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. On gasoline engine models, the Front Control Module (FCM) provides a five volt reference signal to the A/C pressure transducer, then monitors the output voltage of the A/C pressure transducer on a sensor return circuit to determine refrigerant pressure. The FCM broadcasts a refrigerant pressure message to the Powertrain Control Module (PCM), which is programmed to respond to the A/C pressure transducer and other sensor inputs by controlling the operation of the A/C compressor clutch and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM will disengage the A/C compressor clutch when high side pressure rises above 3275 kPa (475 psi) and re-engage the clutch when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer will also disengage the A/C compressor clutch if the high side pressure drops below 193 kPa (28 psi) and will re-engage the clutch when the high side pressure rises above 234 kPa (34 psi). If the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. The A/C pressure transducer message to the PCM will also prevent the A/C compressor clutch from engaging when ambient temperatures are below about 4.5° C (40° F) due to the pressure/temperature relationship of the refrigerant. See Electric A/C Condenser Cooling Fan Switch Point charts for condenser cooling fan on/off pressures. On Hybrid Electric Vehicle (HEV) models, the A/C-heater control receives the A/C pressure transducer signal from the FCM. The A/C-heater control will then do the following based on head pressure: - <= 2.0 Bar (29 psi) Disable compressor for low charge - > 2.5 Bar (36 psi) Enable compressor - >= 28 Bar (406 psi) Reduce compressor speed to reduce head pressure - >= 29.5 Bar (427 psi) Shut down compressor due to high head pressure - < 21 Bar (306 psi) Re-enable compressor if previously shut down The A/C pressure transducer is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if inoperative or damaged. ELECTRIC A/C CONDENSER COOLING FAN SWITCH POINT - 3.7L/4.7L/5.7L GAS ENGINES ELECTRIC A/C CONDENSER COOLING FAN SWITCH POINT - 5.7L HEV ENGINE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Front A/C Pressure Transducer - Removal Refrigerant Pressure Sensor / Switch: Service and Repair Front A/C Pressure Transducer Removal REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2). 3. Remove the A/C pressure transducer from the A/C discharge line (3). 4. Remove the O-ring seal (4) from the discharge line fitting and discard. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Front A/C Pressure Transducer - Removal > Page 7472 Refrigerant Pressure Sensor / Switch: Service and Repair Front A/C Pressure Transducer Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the discharge line fitting. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay Blower Motor Relay: Locations Front Blower Motor Relay Front Blower Motor Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Locations > Front Blower Motor Relay > Page 7478 Blower Motor Relay: Locations Rear Blower Motor Relay Rear Blower Motor Relay is located in the Junction Block (JB). Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Relay-Blower Motor-Front Blower Motor Relay: Diagrams Relay-Blower Motor-Front Connector (IN PDC) RELAY-BLOWER MOTOR-FRONT (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams > Relay-Blower Motor-Front > Page 7481 Blower Motor Relay: Diagrams Relay-Blower Motor-Rear Connector (IN JB) RELAY-BLOWER MOTOR-REAR (IN JB) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay - Description Blower Motor Relay: Description and Operation Front Blower Motor Relay - Description DESCRIPTION The blower motor relay (1) for the standard front heating-A/C system is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal function and patterns (2). The front blower motor relay is a electromechanical device that switches battery current from a fuse in the power distribution center (PDC) directly to the front blower motor when equipped with the manual temperature control (MTC) system, or the blower motor power module when equipped with the automatic temperature control (ATC) system. The front blower motor relay is energized when the relay coil is provided a ground circuit through the integrated power module. The front blower motor relay is located in the power distribution center (PDC) in the engine compartment. Refer to the PDC label for front blower motor relay identification and location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay - Description > Page 7484 Blower Motor Relay: Description and Operation Front Blower Motor Relay - Operation OPERATION The ISO-standard front blower motor relay is an electromechanical switch that uses a low current input from the battery to control the high current output to the front blower motor. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the front blower motor. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The front blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the power distribution center (PDC). The inputs and outputs of the front blower motor relay include: - The common feed terminal (30) receives battery current through a fuse in the PDC at all times. - The coil ground terminal (85) receives a ground circuit through the integrated power module. - The coil battery terminal (86) receives battery current through a fuse in the PDC at all times. - The normally open terminal (87) provides battery current output to the front blower motor when equipped with the manual temperature control (MTC) system, or the blower motor power module when equipped with the automatic temperature control (ATC) system only when the front blower motor relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the front blower motor relay coil is de-energized. The front blower motor relay cannot be adjusted or repaired and must be replaced if inoperative or damaged. See Wiring Information for diagnosis and testing of the blower motor relay and for complete HVAC wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay - Description > Page 7485 Blower Motor Relay: Description and Operation Rear Blower Motor Relay - Description DESCRIPTION The blower motor relay (1) for the rear heating-A/C system is a International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal function and patterns (2). The rear blower motor relay is a electromechanical device that switches battery current from a fuse in the junction block directly to the rear blower motor. The rear blower motor relay is energized when the relay coil is provided a voltage signal by the ignition switch. The rear blower motor relay is located in the junction block (JB) in the passenger compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Description and Operation > Front Blower Motor Relay - Description > Page 7486 Blower Motor Relay: Description and Operation Rear Blower Motor Relay - Operation OPERATION The ISO-standard rear blower motor relay is an electromechanical switch that uses a low current input from the ignition switch to control the high current output to the rear blower motor. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the rear blower motor. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear blower motor relay terminals are connected to the vehicle electrical system through a receptacle in the junction block (JB). The inputs and outputs of the rear blower motor relay include: - The common feed terminal (30) receives fused battery current at all times. - The coil ground terminal (85) is connected to a ground at all times. - The coil battery terminal (86) receives battery current from a fuse in the junction block (JB) through an ignition switch output (run) circuit only when the ignition switch is in RUN. - The normally open terminal (87) provides battery current output to the rear blower motor through the rear blower motor relay output circuit only when the rear blower motor relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the rear blower motor relay coil is de-energized. The rear blower motor relay cannot be adjusted or repaired and must be replaced if inoperative or damaged. See Wiring Information for diagnosis and testing of the rear blower motor relay and for complete HVAC wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair > Front Blower Motor Relay - Removal Blower Motor Relay: Service and Repair Front Blower Motor Relay - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Locate the power distribution center (PDC) (1). 3. Open the PDC cover (2). NOTE: Refer to the fuse and relay layout map on the inner surface of the PDC cover for rear blower motor relay identification and location. 4. Remove the rear blower motor relay (3) from the PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair > Front Blower Motor Relay - Removal > Page 7489 Blower Motor Relay: Service and Repair Front Blower Motor Relay - Installation INSTALLATION NOTE: Refer to the fuse and relay layout map on the inner surface of the PDC cover for rear blower motor relay identification and location. 1. Position the rear blower motor relay (3) into the proper receptacle of the PDC (1). 2. Align the rear blower motor relay terminals with the terminal cavities in the PDC receptacle and push down firmly on the relay until the terminals are fully seated. 3. Close the PDC cover (2). 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair > Front Blower Motor Relay - Removal > Page 7490 Blower Motor Relay: Service and Repair Rear Blower Motor Relay - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Locate the junction block (JB) (1) on the left side of the passenger compartment behind the cowl side trim panel. 3. Remove the rear blower motor relay (2) from the JB. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Service and Repair > Front Blower Motor Relay - Removal > Page 7491 Blower Motor Relay: Service and Repair Rear Blower Motor Relay - Installation INSTALLATION 1. Position the rear blower motor relay (2) into the proper receptacle of the junction block (JB) (1). 2. Align the rear blower motor relay terminals with the terminal cavities in the JB receptacle and push down firmly on the relay until the terminals are fully seated. 3. Reinstall the cowl side trim panel. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations A/C Clutch Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > A/C Clutch Relay - Description Compressor Clutch Relay: Description and Operation A/C Clutch Relay - Description DESCRIPTION The A/C clutch relay (1) is a International Standards Organization (ISO) micro-relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The ISO micro-relay terminal functions are the same as a conventional ISO relay. However, the ISO micro-relay terminal pattern (or footprint) is different, the current capacity is lower, and the physical dimensions are smaller than those of the conventional ISO relay. The A/C clutch relay is located in the power distribution center (PDC) in the engine compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Description and Operation > A/C Clutch Relay - Description > Page 7497 Compressor Clutch Relay: Description and Operation A/C Clutch Relay - Operation OPERATION The ISO-standard A/C clutch micro-relay is an electromechanical switch that uses a low current input controlled by the powertrain control module (PCM) to control the high current output to the A/C clutch field coil. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the A/C clutch field coil. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The A/C clutch relay terminals are connected to the vehicle electrical system through a receptacle in the power distribution center (PDC). The inputs and outputs of the A/C clutch relay include: - The common feed terminal (30) receives fused battery current at all times. - The coil ground terminal (85) receives a ground input from the PCM through the A/C clutch relay control circuit only when the PCM electronically pulls the control circuit to ground. - The coil battery terminal (86) receives fused battery current through a ignition switch output (run-start) circuit only when the ignition switch is in the On or Start positions. - The normally open terminal (87) provides a battery current output to the A/C clutch coil through the A/C clutch relay output circuit only when the compressor clutch relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the A/C clutch relay coil is de-energized. The A/C clutch relay cannot be adjusted or repaired and must be replaced if inoperative or damaged. See Wiring Information for diagnosis and testing of the A/C clutch relay and for complete HVAC wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Service and Repair > A/C Clutch Relay - Removal Compressor Clutch Relay: Service and Repair A/C Clutch Relay - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Locate the power distribution center (PDC) (1). 3. Open the PDC cover (2). NOTE: Refer to the fuse and relay map on the inside of the PDC cover for A/C clutch relay location. 4. Remove the A/C clutch relay (3) from the PDC. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Service and Repair > A/C Clutch Relay - Removal > Page 7500 Compressor Clutch Relay: Service and Repair A/C Clutch Relay - Installation INSTALLATION NOTE: Refer to the fuse and relay map on the inside of the PDC cover for A/C clutch relay location. 1. Position the A/C clutch relay (3) into the proper receptacle of the PDC (1). 2. Align the A/C clutch relay terminals with the terminal cavities in the PDC receptacle and push down firmly on the relay until the terminals are fully seated. 3. Close the PDC cover (2). 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up Control Module HVAC: Customer Interest A/C - Does Not Cool Sufficiently/Evaporator Ices Up NUMBER: 24-010-08 GROUP: Air Conditioning DATE: December 19, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.04 OR HIGHER. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: FLASH: Evaporator Freeze Up In A/C Equipped Vehicles OVERVIEW: This Bulletin involves reprogramming the Automatic Temperature Control module with new software. MODELS: 2009 (HB) Durango (HEV Only) 2009 (HG) Aspen(HEV Only) NOTE: This bulletin applies to vehicles equipped with HEV engine (sales code EZE) and Automatic Temperature Control (ATC) ATC (sales code HAF). SYMPTOM/CONDITION: Some customers may experience an intermittent condition where air flow from the HVAC vents is warmer than desired while driving with the HVAC system on. This may be due to evaporator freeze up. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) using the appropriate Diagnostic Procedures available in TechCONNECT, verify all ATC systems are functioning as designed. If DTC's are present record them on a repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is experienced or described by the customer, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 9.04 level software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up > Page 7509 "DealerCONNECT > Service> StarSCAN(R) and StarMOBILE(R) tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old HVAC part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the HVAC in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash HVAC" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash HVAC" screen has updated to the new part number. NOTE: Due to the HVAC programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 7. Verify proper performance of HVAC system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Customer Interest for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up > Page 7510 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up Control Module HVAC: All Technical Service Bulletins A/C - Does Not Cool Sufficiently/Evaporator Ices Up NUMBER: 24-010-08 GROUP: Air Conditioning DATE: December 19, 2008 THE StarSCAN(R) FLASH FILES FOR THIS BULLETIN MUST BE RETRIEVED FROM THE INTERNET. StarSCAN(R) SOFTWARE LEVEL MUST BE AT RELEASE 9.04 OR HIGHER. StarMOBILE DESKTOP CLIENT MAY ALSO BE USED TO PERFORM THIS PROCEDURE. StarMOBILE STANDALONE MODE MAY ALSO BE USED TO PERFORM THE FLASH. SUBJECT: FLASH: Evaporator Freeze Up In A/C Equipped Vehicles OVERVIEW: This Bulletin involves reprogramming the Automatic Temperature Control module with new software. MODELS: 2009 (HB) Durango (HEV Only) 2009 (HG) Aspen(HEV Only) NOTE: This bulletin applies to vehicles equipped with HEV engine (sales code EZE) and Automatic Temperature Control (ATC) ATC (sales code HAF). SYMPTOM/CONDITION: Some customers may experience an intermittent condition where air flow from the HVAC vents is warmer than desired while driving with the HVAC system on. This may be due to evaporator freeze up. DIAGNOSIS: Using a Scan Tool (StarSCAN(R)) using the appropriate Diagnostic Procedures available in TechCONNECT, verify all ATC systems are functioning as designed. If DTC's are present record them on a repair order and repair as necessary before proceeding further with this bulletin. If the Symptom/Condition is experienced or described by the customer, perform the Repair Procedure. SPECIAL TOOLS / EQUIPMENT REQUIRED: REPAIR PROCEDURE - USING THE INTERNET TO RETRIEVE THE FLASH FILE: NOTE: When performing this Repair Procedure, the software release level in the StarSCAN(R); must be programmed with 9.04 level software or higher. The software release level is visible in the blue header at the top of the StarSCAN(R) screen. NOTE: The StarSCAN(R) diagnostic scan tool fully supports Internet connectivity. However, to take advantage of this feature you must first configure the StarSCAN(R) for your dealership's network. Make sure the StarSCAN(R) is configured to the dealership's network before proceeding. For instruction on setting up your StarSCAN(R) for the dealer's network refer to either: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up > Page 7516 "DealerCONNECT > Service> StarSCAN(R) and StarMOBILE(R) tools > Online Documentation", or refer to the StarSCAN(R) Quick Start Networking Guide. The StarSCAN(R) Quick Start Networking Guide is also available on the website under the "Download Center". NOTE: If this flash process is interrupted/aborted, the flash should be restarted. 1. Install a battery charger and verify that the charging rate provides approximately 13.5 volts. Set the battery charger to continuous charge. Do not allow the charger to time out during the flash process. Remove the charger from the battery when the flash process is complete. 2. Connect the CH9410 StarSCAN(R) ethernet cable to the StarSCAN(R) and the dealer's network drop. 3. Connect the CH9404D StarSCAN(R) vehicle cable to the StarSCAN(R) and the vehicle. 4. Power ON the StarSCAN(R). 5. Turn the ignition switch on. 6. Retrieve the old HVAC part number. Using the StarSCAN(R) at the "Home screen: a. Select "ECU View" b. Touch the screen to highlight the HVAC in the list of modules. c. Select "More Options" d. Select "ECU Flash" e. Record the part number at the top of the "Flash HVAC" screen for later reference. f. Select "Browse for New File". Follow the on screen instructions. g. Select "Download to Scantool". h. Select "Close" after the download is complete, then select "Back". i. Highlight the listed calibration. j. Select "Update Controller". Follow on screen instructions. k. When the update is complete, select "OK". l. Verify the part number at the top of the "Flash HVAC" screen has updated to the new part number. NOTE: Due to the HVAC programming procedure, a DTC may be set in other modules (TCM, BCM, MIC, SKREEM, etc.) within the vehicle, if so equipped. Some DTC's may cause the MIL to illuminate. From the "Home" screen select "System View". Then select "All DTCs". Press "Clear All Stored DTCs" if there are any DTCs shown on the list. 7. Verify proper performance of HVAC system. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 24-010-08 > Dec > 08 > A/C - Does Not Cool Sufficiently/Evaporator Ices Up > Page 7517 FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Technical Service Bulletins > Page 7518 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Front Blower Motor Power Module C1 (ATC) Control Module HVAC: Diagrams Front Blower Motor Power Module C1 (ATC) Connector C1 (ATC) MODULE-POWER-BLOWER MOTOR-FRONT (ATC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Diagrams > Front Blower Motor Power Module C1 (ATC) > Page 7521 Control Module HVAC: Diagrams Front Blower Motor Power Module C2 (ATC) Connector C2 (ATC) MODULE-POWER-BLOWER MOTOR-FRONT (ATC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description Control Module HVAC: Description and Operation Front Blower Motor Power Module - Description DESCRIPTION A blower motor power module is used on this model when it is equipped with the automatic temperature control (ATC) heating-A/C system. Models equipped with the manual temperature control (MTC) heating-A/C system use a blower motor resistor block, instead of the blower motor power module . The blower motor power module is mounted to the rear of the HVAC housing, directly behind the glove box. The blower motor power module consists of a molded plastic mounting plate with two integral connector receptacles (1). Concealed behind the mounting plate is the power module electronic circuitry and a large finned heat sink (2). The blower motor power module is accessed for service from beneath the right side of the instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Description and Operation > Front Blower Motor Power Module - Description > Page 7524 Control Module HVAC: Description and Operation Front Blower Motor Power Module - Operation OPERATION The blower motor power module is connected to the vehicle electrical system through a dedicated lead and connector of the HVAC wire harness. A second connector receptacle receives the wire harness connector from the blower motor. The blower motor power module allows the microprocessor-based Automatic Temperature Control (ATC) A/C-heater control to calculate and provide infinitely variable blower motor speeds based upon either manual blower switch input or the ATC programming using a Pulse Width Modulated (PWM) circuit strategy. The PWM voltage is applied to a comparator circuit that compares the PWM signal voltage to the blower motor feedback voltage. The resulting output drives the power module circuitry, which provides a linear output voltage to change or maintain the desired blower speed. The blower motor power module is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The blower motor power module cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal Control Module HVAC: Service and Repair Front Blower Motor Power Module - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. WARNING: The heat sink for the blower motor power module may get very hot during normal operation. If the blower motor was turned on prior to servicing the blower motor power module, wait five minutes to allow the heat sink to cool before performing diagnosis or service. Failure to take this precaution may result in possible serious injury. 1. Disconnect and isolate the negative battery cable. 2. If equipped with a trim cover (2), remove the two screws (1) that secure the trim cover over the blower motor power module (3) located below the right side of the instrument panel and remove the cover. 3. Disconnect the two wire harness connectors (1) from the blower motor power module (2). 4. Remove the two screws (3) that secure the blower motor power module to the front HVAC housing (4). 5. Remove the blower motor power module from the front HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair > Front Blower Motor Power Module - Removal > Page 7527 Control Module HVAC: Service and Repair Front Blower Motor Power Module - Installation INSTALLATION 1. Position the blower motor power module (2) into the front HVAC housing (4). 2. Install the two screws (3) that secure the blower motor power module to the front HVAC housing. Tighten the screws to 2 Nm (17 in. lbs.). 3. Connect the two wire harness connectors (1) to the blower motor power module. 4. If equipped with a trim cover (2), install the trim cover over the blower motor power module (3) and install the two retaining screws (1). Tighten the screws to 2 Nm (17 in. lbs.). 5. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Ambient Air Temperature Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Ambient Air Temperature Sensor > Page 7533 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7534 Ambient Temperature Sensor / Switch HVAC: Diagrams Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-AMBIENT AIR TEMPERATURE - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Front Ambient Temperature Sensor - Description Ambient Temperature Sensor / Switch HVAC: Description and Operation Front Ambient Temperature Sensor - Description DESCRIPTION The ambient air temperature sensor is a variable resistor that monitors the air temperature outside of the vehicle. The ambient air temperature sensor is mounted onto the inside of the front bumper beam and its data is used by the heating-A/C system to maintain optimum cabin temperature levels. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Description and Operation > Front Ambient Temperature Sensor - Description > Page 7537 Ambient Temperature Sensor / Switch HVAC: Description and Operation Front Ambient Temperature Sensor - Operation OPERATION The ambient air temperature sensor is a variable resistor that operates on a ground circuit and a 5-volt reference signal circuit sent by the front control module (FCM) through a two-wire lead and connector of the vehicle wire harness. The ambient air temperature sensor changes its internal resistance in response to changes in the outside air temperature, which either increases or decreases the reference signal voltage read by the FCM. The FCM converts and broadcasts the sensor data over the controller area network (CAN) B bus, where it is read by the A/C-heater control and other various vehicle control modules. The ambient air temperature sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The ambient air temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged See: Instrument Panel, Gauges and Warning Indicators/Outside Temperature Display/Outside Temperature Display Sensor/Service and Repair/Ambient Temperature Sensor - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed Evaporator Temperature Sensor / Switch: Customer Interest A/C - No A/C After Long Trip With Blower On Low Speed NUMBER: 24-004-10 GROUP: Heating & Air Conditioning DATE: April 7, 2010 SUBJECT: No A/C Or Evaporator Freeze Up On Long Trips With Blower In Low Speed Position OVERVIEW: This bulletin involves adding a resistor 470 ohm resistor in the evaporator temperature sensor signal circuit. MODELS: 2004-2009 (HB) Durango 2007-2009 (HG) Aspen NOTE: This bulletin applies to all HB/HG vehicles with A/C (sales code HAA or HAB or HAF). This bulletin does not cover the 2009 HG HEV vehicle. SYMPTOM/CONDITION: The customers may experience poor A/C, little to no A/C operation or reduced airflow from the instrument panel vents. This condition often occurs after a extended drive cycle (greater that 2 hours) with the A/C on and the blower speed is set to the low position. Once the vehicle is shut off or the A/C is turned off for approximately 2 hours the A/C will operate normally. Adding the resistor to the evaporator temperature sensor signal wire allows the A/C Compressor to cycle at a higher temperature more frequently to avoid this condition. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all A/C systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and disconnect the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 - Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Removal Procedures. 2. Using the wiring diagrams available in DealerCONNECT/TechCONNECT locate the evaporator temperature sensor signal wire. Cavity 10 of the C2 black 12 - way connector for ATC systems. Cavity 2 of 20 - way black C1 connector for MTC systems. 3. Measure 76mm (3 inches) down from end of ATC/MTC connector and cut the evaporator temperature sensor signal wire. 4. Using the 2 splice crimps and 2 wire shrink wraps from resistor kit p/n 68064996AA splice in the 470 ohm resistor. Follow the detailed wiring procedures available in DealerCONNECT/TechCONNECT, Refer To the Wiring Tab > 8W-01 Wiring Diagram Information > Wire > Standard Procedure. NOTE: Be sure to use the splice crimps and shrink wrap on wires and resistor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Temperature Sensor / Switch: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed > Page 7546 5. Install the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Installation Procedures. 6. Using the wiTECH(TM) or StarSCAN(R) erase all DTC. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed Evaporator Temperature Sensor / Switch: All Technical Service Bulletins A/C - No A/C After Long Trip With Blower On Low Speed NUMBER: 24-004-10 GROUP: Heating & Air Conditioning DATE: April 7, 2010 SUBJECT: No A/C Or Evaporator Freeze Up On Long Trips With Blower In Low Speed Position OVERVIEW: This bulletin involves adding a resistor 470 ohm resistor in the evaporator temperature sensor signal circuit. MODELS: 2004-2009 (HB) Durango 2007-2009 (HG) Aspen NOTE: This bulletin applies to all HB/HG vehicles with A/C (sales code HAA or HAB or HAF). This bulletin does not cover the 2009 HG HEV vehicle. SYMPTOM/CONDITION: The customers may experience poor A/C, little to no A/C operation or reduced airflow from the instrument panel vents. This condition often occurs after a extended drive cycle (greater that 2 hours) with the A/C on and the blower speed is set to the low position. Once the vehicle is shut off or the A/C is turned off for approximately 2 hours the A/C will operate normally. Adding the resistor to the evaporator temperature sensor signal wire allows the A/C Compressor to cycle at a higher temperature more frequently to avoid this condition. DIAGNOSIS: Using a Scan Tool (wiTECH(TM) or StarSCAN(R)) with the appropriate Diagnostic Procedures available in TechCONNECT, verify all A/C systems are functioning as designed. If DTC's are present record them on the repair order and repair as necessary before proceeding further with this bulletin. If the above condition is present, perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Remove and disconnect the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 - Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Removal Procedures. 2. Using the wiring diagrams available in DealerCONNECT/TechCONNECT locate the evaporator temperature sensor signal wire. Cavity 10 of the C2 black 12 - way connector for ATC systems. Cavity 2 of 20 - way black C1 connector for MTC systems. 3. Measure 76mm (3 inches) down from end of ATC/MTC connector and cut the evaporator temperature sensor signal wire. 4. Using the 2 splice crimps and 2 wire shrink wraps from resistor kit p/n 68064996AA splice in the 470 ohm resistor. Follow the detailed wiring procedures available in DealerCONNECT/TechCONNECT, Refer To the Wiring Tab > 8W-01 Wiring Diagram Information > Wire > Standard Procedure. NOTE: Be sure to use the splice crimps and shrink wrap on wires and resistor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Temperature Sensor / Switch: > 24-004-10 > Apr > 10 > A/C - No A/C After Long Trip With Blower On Low Speed > Page 7552 5. Install the ATC or MTC control head. Follow the detailed service procedures available in DealerCONNECT/TechCONNECT, Refer To Group 24 Heating & Air Conditioning > Controls, Front > Controls, A/C & Heater Installation Procedures. 6. Using the wiTECH(TM) or StarSCAN(R) erase all DTC. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Page 7553 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Technical Service Bulletins > Page 7554 Evaporator Temperature Sensor / Switch: Diagrams Connector - 2 WAY SENSOR-EVAPORATOR TEMPERATURE - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Front Evaporator Temperature Sensor Description Evaporator Temperature Sensor / Switch: Description and Operation Front Evaporator Temperature Sensor - Description DESCRIPTION The evaporator temperature sensor (1) is an electrical thermistor located within a molded plastic case that is inserted into the HVAC housing (2) to measure the temperature of the conditioned air downstream of the A/C evaporator (3). Two terminals within the connector receptacle connect the sensor to the vehicle electrical system through a wire lead and connector of the HVAC wire harness. NOTE: Cutaway of typical HVAC housing shown for clarity in illustration. The external location of the evaporator temperature sensor allows the sensor to be removed or installed without disturbing the refrigerant in the A/C system. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Description and Operation > Front Evaporator Temperature Sensor Description > Page 7557 Evaporator Temperature Sensor / Switch: Description and Operation Front Evaporator Temperature Sensor - Operation OPERATION The evaporator temperature sensor monitors the temperature of the conditioned air downstream of the A/C evaporator and supplies an input signal to the A/C-heater control. The A/C-heater control uses the evaporator temperature sensor input signal to optimize A/C system performance and to protect the A/C system from evaporator freezing. The evaporator temperature sensor will change its internal resistance in response to the temperatures it monitors and is connected to the A/C-heater control through sensor ground circuit and a 5-volt reference signal circuit. As the temperature of the A/C evaporator decreases, the internal resistance of the evaporator temperature sensor decreases. On gasoline engine equipped models, the A/C-heater control uses the monitored voltage reading as an indication of evaporator temperature and that conditions are correct to broadcast an A/C request message on the Controller Area Network (CAN) B bus, where it is read by the Front Control Module (FCM). The FCM then requests the Powertrain Control Module (PCM) to cycle the A/C compressor clutch as necessary over the CAN C bus. On Hybrid Electric Vehicle (HEV) models, the A/C-heater control calculates an evaporator temperature target based on A/C load. This target temperature is compared with the actual evaporator temperature sensor value. Based on this comparison, the A/C-heater control sends out a compressor target RPM speed over the CAN B bus to the FCM. The FCM then ports the target message to the electric A/C compressor over the CAN C bus. If the A/C-heater control does not receive the electric A/C compressor messages, a Diagnostic Trouble Code (DTC) will be set. The evaporator temperature sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The evaporator temperature sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Front Evaporator Temperature Sensor - Removal Evaporator Temperature Sensor / Switch: Service and Repair Front Evaporator Temperature Sensor - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. NOTE: Take the proper precautions to protect the front face of the instrument panel from cosmetic damage during this service procedure. 1. Disconnect and isolate the negative battery cable. 2. Remove the instrument panel assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Removal. 3. Disconnect the HVAC wire harness connector (1) from the evaporator temperature sensor (2) located on the top of the HVAC housing (3) near the blend door actuator (4). 4. Remove the evaporator temperature sensor from the HVAC housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Service and Repair > Front Evaporator Temperature Sensor - Removal > Page 7560 Evaporator Temperature Sensor / Switch: Service and Repair Front Evaporator Temperature Sensor - Installation INSTALLATION 1. Install the evaporator temperature sensor (2) into the opening in the HVAC housing (3) near the blend door actuator (4). 2. Connect the HVAC wire harness connector (1) to the evaporator temperature sensor. 3. Install the instrument panel assembly See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel - Installation. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Locations > Page 7564 Humidity Sensor: Diagrams Connector - (MIRROR JUMPER) 4 WAY SENSOR-HUMIDITY - (MIRROR JUMPER) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Description and Operation > Humidity Sensor - Description Humidity Sensor: Description and Operation Humidity Sensor - Description DESCRIPTION A humidity sensor (1) is used on HEV models to detect humidity levels inside the vehicle to optimize the dehumidifying effect of the A/C system, which reduces electronic air conditioning (EAC) power consumption. The humidity sensor attaches to the interior rear view mirror base (2) and is connected to the vehicle electrical system by a wire lead and connector of the mirror wire harness (3). The humidity sensor can be serviced from the interior rear view mirror without the use of any special tools. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Description and Operation > Humidity Sensor - Description > Page 7567 Humidity Sensor: Description and Operation Humidity Sensor - Operation OPERATION The humidity sensor detects humidity, dew point, windshield temperature and infrared sensor data and sends this information to the Hybrid Gateway Module (HGM) via a Local Interconnect Network (LIN) bus connection. The HGM then sends the message via the Controller Area Network (CAN) C bus to the Front Control Module (FCM), which ports the message to the A/C-heater control over the CAN B bus. If the humidity sensor message is not received by the A/C-heater control, the evaporator logic will be disabled, the evaporator target will be set to 3.3° C (38° F) and a Diagnostic Trouble Code (DTC) will set. The information the A/C-heater control receives from the humidity sensor can be viewed using a scan tool. The humidity sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The humidity sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Service and Repair > Humidity Sensor - Removal Humidity Sensor: Service and Repair Humidity Sensor - Removal REMOVAL 1. Disconnect and isolate the negative battery cable 2. Remove the inside rear view mirror from the front glass See: Body and Frame/Mirrors/Service and Repair/Interior Rearview Mirror - Removal 3. Disconnect the retaining tabs that secure the humidity sensor (1) to the mirror base (2) and slide the sensor off the base. 4. Disconnect the wire harness connector (3) from the humidity sensor and remove the sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Humidity Sensor > Component Information > Service and Repair > Humidity Sensor - Removal > Page 7570 Humidity Sensor: Service and Repair Humidity Sensor - Installation INSTALLATION 1. Connect the mirror wire harness (3) to the humidity sensor (1). 2. Position the humidity sensor onto the rear view mirror base (2) and engage the retaining tabs. Make sure the retaining tabs are fully engaged. 3. Install the interior rear view mirror See: Body and Frame/Mirrors/Service and Repair/Interior Rearview Mirror - Installation. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7574 Refrigerant Pressure Sensor / Switch: Diagrams Connector - (HEADLAMP AND DASH) 4 WAY TRANSDUCER-A/C PRESSURE - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Front A/C Pressure Transducer - Description Refrigerant Pressure Sensor / Switch: Description and Operation Front A/C Pressure Transducer Description DESCRIPTION The A/C pressure transducer (1) is a switch that is installed on a fitting located on the A/C discharge line. An internally threaded fitting on the A/C pressure transducer connects it to the externally threaded Schrader-type fitting on the A/C discharge line. A rubber O-ring seals the connection between the A/C pressure transducer and the discharge line fitting. The A/C pressure transducer is connected to the vehicle electrical system by a molded plastic connector with three terminals. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > Front A/C Pressure Transducer - Description > Page 7577 Refrigerant Pressure Sensor / Switch: Description and Operation Front A/C Pressure Transducer Operation OPERATION The A/C pressure transducer monitors the pressures in the high side of the refrigerant system through its connection to a fitting on the discharge line. The A/C pressure transducer will change its internal resistance in response to the pressures it monitors. A Schrader-type valve in the discharge line fitting permits the A/C pressure transducer to be removed or installed without disturbing the refrigerant in the A/C system. On gasoline engine models, the Front Control Module (FCM) provides a five volt reference signal to the A/C pressure transducer, then monitors the output voltage of the A/C pressure transducer on a sensor return circuit to determine refrigerant pressure. The FCM broadcasts a refrigerant pressure message to the Powertrain Control Module (PCM), which is programmed to respond to the A/C pressure transducer and other sensor inputs by controlling the operation of the A/C compressor clutch and the radiator cooling fan to help optimize A/C system performance and to protect the system components from damage. The PCM will disengage the A/C compressor clutch when high side pressure rises above 3275 kPa (475 psi) and re-engage the clutch when high side pressure drops below 1999 kPa (290 psi). The A/C pressure transducer will also disengage the A/C compressor clutch if the high side pressure drops below 193 kPa (28 psi) and will re-engage the clutch when the high side pressure rises above 234 kPa (34 psi). If the refrigerant pressure rises above 1655 kPa (240 psi), the PCM will actuate the cooling fan. The A/C pressure transducer message to the PCM will also prevent the A/C compressor clutch from engaging when ambient temperatures are below about 4.5° C (40° F) due to the pressure/temperature relationship of the refrigerant. See Electric A/C Condenser Cooling Fan Switch Point charts for condenser cooling fan on/off pressures. On Hybrid Electric Vehicle (HEV) models, the A/C-heater control receives the A/C pressure transducer signal from the FCM. The A/C-heater control will then do the following based on head pressure: - <= 2.0 Bar (29 psi) Disable compressor for low charge - > 2.5 Bar (36 psi) Enable compressor - >= 28 Bar (406 psi) Reduce compressor speed to reduce head pressure - >= 29.5 Bar (427 psi) Shut down compressor due to high head pressure - < 21 Bar (306 psi) Re-enable compressor if previously shut down The A/C pressure transducer is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The A/C pressure transducer cannot be adjusted or repaired and must be replaced if inoperative or damaged. ELECTRIC A/C CONDENSER COOLING FAN SWITCH POINT - 3.7L/4.7L/5.7L GAS ENGINES ELECTRIC A/C CONDENSER COOLING FAN SWITCH POINT - 5.7L HEV ENGINE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Front A/C Pressure Transducer - Removal Refrigerant Pressure Sensor / Switch: Service and Repair Front A/C Pressure Transducer Removal REMOVAL NOTE: It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer. 1. Disconnect and isolate the negative battery cable. 2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2). 3. Remove the A/C pressure transducer from the A/C discharge line (3). 4. Remove the O-ring seal (4) from the discharge line fitting and discard. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > Front A/C Pressure Transducer - Removal > Page 7580 Refrigerant Pressure Sensor / Switch: Service and Repair Front A/C Pressure Transducer Installation INSTALLATION NOTE: Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor. 1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3). 2. Install the A/C pressure transducer (2) onto the discharge line fitting. Tighten the A/C pressure transducer securely. 3. Connect the wire harness connector (1) to the A/C pressure transducer. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Infrared Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Locations > Infrared Sensor > Page 7585 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Infrared Sensor (Headliner) 4 Way Solar Sensor: Diagrams Infrared Sensor (Headliner) 4 Way Connector - (HEADLINER) 4 WAY SENSOR-INFRARED - (HEADLINER) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Diagrams > Infrared Sensor (Headliner) 4 Way > Page 7588 Solar Sensor: Diagrams Sun Sensor (Instrument Panel) 4 Way Connector - (INSTRUMENT PANEL) 4 WAY SENSOR-SUN - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description Solar Sensor: Description and Operation Infrared Temperature Sensor - Description DESCRIPTION The infrared sensor consists of an infrared transducer (1) located in the overhead console. The infrared sensor is used only on models equipped with the automatic temperature control (ATC) heater-A/C system. The infrared transducer is contained within a black molded plastic housing (2) with an integral wire connector receptacle (3). The integral mounting tab (4) allows the infrared sensor to be secured with one screw to the overhead console. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 7591 Solar Sensor: Description and Operation Infrared Temperature Sensor - Operation OPERATION The infrared sensor detects thermal radiation emitted by the front seat occupants and surroundings and converts its data into a linear pulse width modulated (PWM) output signal, which is sent to the compass temperature module (EOM) through a two-wire lead and connector of the headliner wire harness. The EOM sends a message over the controller area network (CAN) B bus where it is read by the automatic temperature control (ATC) A/C-heater control. The ATC A/C-heater control uses the infrared sensor data as one of the inputs necessary to automatically control the interior cabin temperature level. By using thermal radiation (surface temperature) measurement, rather than an air temperature measurement, the ATC heating-A/C system is able to adjust itself to the comfort level as perceived by the occupants. This allows the ATC system to compensate for other ambient conditions affecting comfort levels, such as solar heat gain or evaporative heat loss. The ATC system logic responds to the infrared sensor message by calculating and adjusting the air flow temperature and air flow rate needed to properly obtain and maintain the selected comfort level temperature of the occupants. The EOM continually monitors the infrared sensor circuits, and will store a diagnostic trouble code (DTC) for any problem it detects. The infrared sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The infrared sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 7592 Solar Sensor: Description and Operation Sun Sensor - Description DESCRIPTION NOTE: Typical sun sensor assembly shown. The automatic temperature control (ATC) heating-A/C system uses a sun sensor assembly (1) to measure sun light intensity. The sun sensor assembly incorporates two sun sensors (2) within a molded plastic case which is mounted to the instrument panel and a clear lens (3) that protrudes through the defroster grille. The wire harness receptacle (4) connects the sun sensors to the vehicle electrical system through a wire lead and connector of the instrument panel wire harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 7593 Solar Sensor: Description and Operation Sun Sensor - Operation OPERATION The ATC dual-zone heating-A/C system uses two sun sensors to balance the system in response to side-to-side variations in sun light intensity. Passengers in sun and shadow require different functional settings because they experience very different temperatures. The sun sensor assembly provides data to the A/C heater control to help determine proper mode and blend-air door positions and blower motor speeds. The sun sensors are not thermistor type sensors, but rather photo diodes. For this reason the sun sensors responds to sun light intensity rather than temperature. The sun sensor assembly is also used to sense day and night conditions for automatic headlight control, if equipped. The sun sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The sun sensor assembly cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Description and Operation > Page 7594 Solar Sensor: Testing and Inspection SUN SENSOR WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible severe or fatal injury. The sun sensor assembly is located so that the sun rays will hit the sensors in the same way that it will hit the driver and the passenger. It is important that the area in front of the sun sensor assembly be unobstructed. Check for the following: - Windshield wipers are properly adjusted. - Defroster grille and sun sensor is properly installed. The sun sensor lens should protrude above the defroster grille. - Any stickers on the windshield are not directly in front of the sun sensor. - Any items laying on top of the instrument panel are not covering the sun sensor. If the vehicle exhibits a lack of passenger comfort in sunny weather such as in the early afternoon, inspect the position of the sun sensor assembly. The sun sensor lens should protrude above the defroster grille to insure proper operation. If the sun sensor is not properly positioned, perform the following procedure: 1. Confirm that the defroster grille is properly installed. If not, repair as required. 2. Remove the defroster grille and verify that the sun sensor is properly installed to the defroster grill See: Service and Repair/Sun Sensor Installation. 3. Reinstall the defroster grille. The A/C-heater control continually monitors the sun sensor circuits and will store diagnostic trouble codes (DTCs) for any problem it detects. The sun sensor can be tested in the vehicle with a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal Solar Sensor: Service and Repair Infrared Temperature Sensor - Removal REMOVAL NOTE: Typical overhead console shown. Infrared sensor location may vary. 1. Disconnect and isolate the negative battery cable. 2. Remove the overhead console (2) and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Remove the screw (3) that secures the infrared sensor (1) to the overhead console. 4. Remove the infrared sensor from the overhead console. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 7597 Solar Sensor: Service and Repair Infrared Temperature Sensor - Installation INSTALLATION NOTE: Typical overhead console shown. Infrared sensor location may vary. 1. Position the infrared sensor (1) onto the overhead console (2). 2. Install the screw (3) that secures the infrared sensor to the overhead console. Tighten the screw to 2 Nm (17 in. lbs). 3. Install the overhead console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Installation. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 7598 Solar Sensor: Service and Repair Sun Sensor - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the defroster grille (2) from the top of the instrument panel See: Air Register/Service and Repair/Defroster Grille - Removal. 3. Disconnect the wire harness connector (3) from the sun sensor assembly (1). 4. Remove the screw (4) that secures the sun sensor to the bottom of the defroster grill and remove the sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 7599 Solar Sensor: Service and Repair Sun Sensor - Installation INSTALLATION 1. Position the sun sensor assembly (1) to the bottom of the defroster grill (4) and install the retaining screw (4). Tighten the screw securely. 2. Connect the wiring harness connector (3) to the sun sensor assembly. 3. Install the defroster grille See: Air Register/Service and Repair/Defroster Grille - Installation. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation DESCRIPTION Two refrigerant system service ports are used to recover/recycle/evacuate/charge and test the A/C refrigerant system. Unique sizes are used on the service ports for the R-134a refrigerant system to ensure the system is not accidentally contaminated with R-12 refrigerant or service equipment used for R-12 refrigerant. NOTE: On HEV models, the low side service port is partially hidden under the air filter housing See: Engine, Cooling and Exhaust/Engine/Tune-up and Engine Performance Checks/Air Cleaner Housing/Service and Repair/Air Cleaner Body - Removal . The high side service port (5) is located on the A/C liquid line (3) above the A/C receiver/drier (2). The low side service port (6) is located on the A/C suction line (9) at the top of the engine. Both the high side and low side A/C service port valve cores are serviceable. Each of the service ports has a threaded plastic protective cap installed over it from the factory. After servicing the refrigerant system, always reinstall both of the service port caps. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and Repair > Front Service Port Valve Core - Removal Service Port HVAC: Service and Repair Front Service Port Valve Core - Removal REMOVAL WARNING: Review safety precautions and warnings before performing this procedure See: Service Precautions/Warning and See: Service Precautions/Caution . Failure to follow the warnings and cautions may result in serious or fatal injury. NOTE: Typical A/C system service port and refrigerant line shown. 1. Remove the protective cap (1) from the service port (2). 2. Recover the refrigerant from the refrigerant system See: Service and Repair/Refrigerant System Recovery. 3. Using a Schrader-type valve core tool, remove the valve core (3) from the service port. 4. Install a plug in or tape over the opened service port(s). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and Repair > Front Service Port Valve Core - Removal > Page 7605 Service Port HVAC: Service and Repair Front Service Port Valve Core - Installation INSTALLATION NOTE: Typical A/C system service port and refrigerant line shown. 1. Lubricate the valve core (3) with clean refrigerant oil prior to installation. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. 2. Remove the tape or plug from the service port (2). CAUTION: A valve core that is not fully seated in the A/C service port can result in damage to the valve during refrigerant system evacuation and charge. Such damage may result in a loss of system refrigerant while uncoupling the charge adapters. 3. Using a Schrader-type valve core tool, install and tighten the valve core into the service port(s). 4. Evacuate the refrigerant system See: Service and Repair/Refrigerant System Evacuate. 5. Charge the refrigerant system See: Service and Repair/Refrigerant System Charge. NOTE: The protective cap helps aid in service port sealing and helps protects the refrigerant system from contamination. Remember to always reinstall the protective cap onto the service port when refrigerant system service is complete. 6. Install the protective cap (1) onto the service port. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Infrared Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations > Infrared Sensor > Page 7610 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Infrared Sensor (Headliner) 4 Way Solar Sensor: Diagrams Infrared Sensor (Headliner) 4 Way Connector - (HEADLINER) 4 WAY SENSOR-INFRARED - (HEADLINER) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Diagrams > Infrared Sensor (Headliner) 4 Way > Page 7613 Solar Sensor: Diagrams Sun Sensor (Instrument Panel) 4 Way Connector - (INSTRUMENT PANEL) 4 WAY SENSOR-SUN - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description Solar Sensor: Description and Operation Infrared Temperature Sensor - Description DESCRIPTION The infrared sensor consists of an infrared transducer (1) located in the overhead console. The infrared sensor is used only on models equipped with the automatic temperature control (ATC) heater-A/C system. The infrared transducer is contained within a black molded plastic housing (2) with an integral wire connector receptacle (3). The integral mounting tab (4) allows the infrared sensor to be secured with one screw to the overhead console. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 7616 Solar Sensor: Description and Operation Infrared Temperature Sensor - Operation OPERATION The infrared sensor detects thermal radiation emitted by the front seat occupants and surroundings and converts its data into a linear pulse width modulated (PWM) output signal, which is sent to the compass temperature module (EOM) through a two-wire lead and connector of the headliner wire harness. The EOM sends a message over the controller area network (CAN) B bus where it is read by the automatic temperature control (ATC) A/C-heater control. The ATC A/C-heater control uses the infrared sensor data as one of the inputs necessary to automatically control the interior cabin temperature level. By using thermal radiation (surface temperature) measurement, rather than an air temperature measurement, the ATC heating-A/C system is able to adjust itself to the comfort level as perceived by the occupants. This allows the ATC system to compensate for other ambient conditions affecting comfort levels, such as solar heat gain or evaporative heat loss. The ATC system logic responds to the infrared sensor message by calculating and adjusting the air flow temperature and air flow rate needed to properly obtain and maintain the selected comfort level temperature of the occupants. The EOM continually monitors the infrared sensor circuits, and will store a diagnostic trouble code (DTC) for any problem it detects. The infrared sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The infrared sensor cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 7617 Solar Sensor: Description and Operation Sun Sensor - Description DESCRIPTION NOTE: Typical sun sensor assembly shown. The automatic temperature control (ATC) heating-A/C system uses a sun sensor assembly (1) to measure sun light intensity. The sun sensor assembly incorporates two sun sensors (2) within a molded plastic case which is mounted to the instrument panel and a clear lens (3) that protrudes through the defroster grille. The wire harness receptacle (4) connects the sun sensors to the vehicle electrical system through a wire lead and connector of the instrument panel wire harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation > Infrared Temperature Sensor - Description > Page 7618 Solar Sensor: Description and Operation Sun Sensor - Operation OPERATION The ATC dual-zone heating-A/C system uses two sun sensors to balance the system in response to side-to-side variations in sun light intensity. Passengers in sun and shadow require different functional settings because they experience very different temperatures. The sun sensor assembly provides data to the A/C heater control to help determine proper mode and blend-air door positions and blower motor speeds. The sun sensors are not thermistor type sensors, but rather photo diodes. For this reason the sun sensors responds to sun light intensity rather than temperature. The sun sensor assembly is also used to sense day and night conditions for automatic headlight control, if equipped. The sun sensor is diagnosed using a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. The sun sensor assembly cannot be adjusted or repaired and must be replaced if inoperative or damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Description and Operation > Page 7619 Solar Sensor: Testing and Inspection SUN SENSOR WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in an accidental airbag deployment and possible severe or fatal injury. The sun sensor assembly is located so that the sun rays will hit the sensors in the same way that it will hit the driver and the passenger. It is important that the area in front of the sun sensor assembly be unobstructed. Check for the following: - Windshield wipers are properly adjusted. - Defroster grille and sun sensor is properly installed. The sun sensor lens should protrude above the defroster grille. - Any stickers on the windshield are not directly in front of the sun sensor. - Any items laying on top of the instrument panel are not covering the sun sensor. If the vehicle exhibits a lack of passenger comfort in sunny weather such as in the early afternoon, inspect the position of the sun sensor assembly. The sun sensor lens should protrude above the defroster grille to insure proper operation. If the sun sensor is not properly positioned, perform the following procedure: 1. Confirm that the defroster grille is properly installed. If not, repair as required. 2. Remove the defroster grille and verify that the sun sensor is properly installed to the defroster grill See: Service and Repair/Sun Sensor Installation. 3. Reinstall the defroster grille. The A/C-heater control continually monitors the sun sensor circuits and will store diagnostic trouble codes (DTCs) for any problem it detects. The sun sensor can be tested in the vehicle with a scan tool See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal Solar Sensor: Service and Repair Infrared Temperature Sensor - Removal REMOVAL NOTE: Typical overhead console shown. Infrared sensor location may vary. 1. Disconnect and isolate the negative battery cable. 2. Remove the overhead console (2) and place it on a workbench See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Remove the screw (3) that secures the infrared sensor (1) to the overhead console. 4. Remove the infrared sensor from the overhead console. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 7622 Solar Sensor: Service and Repair Infrared Temperature Sensor - Installation INSTALLATION NOTE: Typical overhead console shown. Infrared sensor location may vary. 1. Position the infrared sensor (1) onto the overhead console (2). 2. Install the screw (3) that secures the infrared sensor to the overhead console. Tighten the screw to 2 Nm (17 in. lbs). 3. Install the overhead console See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Installation. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 7623 Solar Sensor: Service and Repair Sun Sensor - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable and wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the negative battery cable. 2. Remove the defroster grille (2) from the top of the instrument panel See: Air Register/Service and Repair/Defroster Grille - Removal. 3. Disconnect the wire harness connector (3) from the sun sensor assembly (1). 4. Remove the screw (4) that secures the sun sensor to the bottom of the defroster grill and remove the sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Service and Repair > Infrared Temperature Sensor - Removal > Page 7624 Solar Sensor: Service and Repair Sun Sensor - Installation INSTALLATION 1. Position the sun sensor assembly (1) to the bottom of the defroster grill (4) and install the retaining screw (4). Tighten the screw securely. 2. Connect the wiring harness connector (3) to the sun sensor assembly. 3. Install the defroster grille See: Air Register/Service and Repair/Defroster Grille - Installation. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair Repairs and Inspections Required After a Collision: Service and Repair SERVICE AFTER A SUPPLEMENTAL RESTRAINT DEPLOYMENT Any vehicle which is to be returned to use following a Supplemental Restraint System (SRS) component deployment must have the deployed restraints replaced. In addition, if the driver airbag has been deployed, the clockspring must be replaced and the steering column must be inspected. See: Steering and Suspension/Steering/Steering Column/Testing and Inspection. If the passenger airbag is deployed, the passenger airbag door must be replaced. The seat belt tensioners are deployed by the same signal that deploys the driver and passenger airbags and must also be replaced if either front airbag has been deployed. If a side curtain airbag has been deployed, the headliner as well as the upper A, B, C and D-pillar trim on the same side of the vehicle as the deployed airbag must be replaced. These components are not intended for reuse and will be damaged or weakened as a result of a SRS component deployment, which may or may not be obvious during a visual inspection. On vehicles with an optional sunroof, the sunroof drain tubes and hoses must be closely inspected following a side curtain airbag deployment. It is also critical that the mounting surfaces and mounting brackets for the Occupant Restraint Controller (ORC), side impact sensors and front impact sensors be closely inspected and restored to their original conditions following any vehicle impact damage. Because the ORC and each impact sensor are used by the SRS to monitor or confirm the direction and severity of a vehicle impact, improper orientation or insecure fastening of these components may cause airbags not to deploy when required, or to deploy when not required. There are two methods by which an airbag or seat belt tensioner may be connected to the vehicle electrical system. The first method involves a short pigtail harness and connector insulator that are integral to the airbag or tensioner unit and are replaced as a unit with the service replacement airbag or seat belt tensioner unit. The second method involves a wire harness takeout and connector insulator (squib circuits) that are connected directly to the air bag or tensioner initiator. The heat created by the initiator during an airbag or tensioner deployment will cause collateral damage to a directly connected wire harness take out and connector insulator. Therefore, these direct-connect type take outs and connector insulators must be repaired following an airbag or seat belt tensioner deployment. See: Service and Repair. All other vehicle components should be closely inspected following any SRS component deployment, but are to be replaced only as required by the extent of the visible damage incurred. AIRBAG SQUIB STATUS Multistage airbags with multiple initiators (squibs) must be checked to determine that all squibs were used during the deployment event. The driver and passenger airbags in this vehicle are deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the driver or passenger squib 1 and squib 2 circuits to the two initiators in the airbag inflators. Typically, both initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event. However, it is possible for only one initiator to be used; therefore, it is always necessary to confirm that both initiators have been used in order to avoid the improper handling or disposal of potentially live pyrotechnic or hazardous materials. The following procedure should be performed using a diagnostic scan tool to verify the status of both airbag squibs before either deployed airbag is removed from the vehicle for disposal. CAUTION: Deployed front airbags having two initiators (squibs) in the airbag inflator may or may not have live pyrotechnic material within the inflator. Do not dispose of these airbags unless you are certain of complete deployment. Refer to the Hazardous Substance Control System for information regarding the potentially hazardous properties of the subject component and the proper safe handling procedures. Then dispose of all non-deployed and deployed airbags and seat belt tensioners in a manner consistent with state, provincial, local and federal regulations. 1. Be certain that the diagnostic scan tool contains the latest version of the proper diagnostic software. Connect the scan tool to the 16-way Data Link Connector (DLC). The DLC is located on the driver side lower edge of the instrument panel, outboard of the steering column. 2. Turn the ignition switch to the ON position. 3. Using the scan tool, read and record the active (current) Diagnostic Trouble Code (DTC) data. Using the active DTC information, refer to the Airbag Squib Status table to determine the status of both driver and passenger airbag squibs. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Page 7629 NOTE: If none of the Driver or Passenger Squib 1 or 2 open are active codes, the status of the airbag squibs is unknown. In this case the airbag should be handled and disposed of as if the squibs were both live. CLEANUP PROCEDURE Following a Supplemental Restraint System (SRS) component deployment, the vehicle interior will contain a powdery residue. This residue consists primarily of harmless particulate by-products of the small pyrotechnic charge that initiates the propellant used to deploy a SRS component. However, this residue may also contain traces of sodium hydroxide powder, a chemical by-product of the propellant material that is used to generate the inert gas that inflates the airbag. Since sodium hydroxide powder can irritate the skin, eyes, nose, or throat, be certain to wear safety glasses, rubber gloves, and a long-sleeved shirt during cleanup. WARNING: To avoid serious or fatal injury, if you experience skin irritation during cleanup, run cool water over the affected area. Also, if you experience irritation of the nose or throat, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Page 7630 1. Begin the cleanup by using a vacuum cleaner to remove any residual powder from the vehicle interior. Clean from outside the vehicle and work your way inside, so that you avoid kneeling or sitting on a non-cleaned area. 2. Be certain to vacuum the heater and air conditioning outlets as well. Run the heater and air conditioner blower on the lowest speed setting and vacuum any powder expelled from the outlets. CAUTION: Deployed front airbags having two initiators (squibs) in the airbag inflator may or may not have live pyrotechnic material within the inflator. Do not dispose of these airbags unless you are certain of complete deployment. Refer to AIRBAG SQUIB STATUS. All damaged, ineffective, or non-deployed Supplemental Restraint System (SRS) components which are replaced on vehicles are to be handled and disposed of properly. If an airbag or seat belt tensioner unit is ineffective or damaged and non-deployed, refer to the Hazardous Substance Control System for information regarding the potentially hazardous properties of the subject component and the proper safe handling procedures. Then dispose of all non-deployed and deployed airbags and seat belt tensioners in a manner consistent with state, provincial, local and federal regulations. 3. Next, remove the deployed SRS components from the vehicle. Refer to the appropriate service removal procedures. 4. You may need to vacuum the interior of the vehicle a second time to recover all of the powder. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib 1 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib 1 > Page 7636 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib 1 > Page 7637 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib 1 > Page 7638 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Locations > Driver Airbag Squib 1 > Page 7639 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Airbag Squib 1 (Clockspring) 2 Way Air Bag: Diagrams Driver Airbag Squib 1 (Clockspring) 2 Way Connector - (CLOCKSPRING) 2 WAY AIRBAG-DRIVER SQUIB 1 - (CLOCKSPRING) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Airbag Squib 1 (Clockspring) 2 Way > Page 7642 Air Bag: Diagrams Driver Airbag Squib 2 (Clockspring) 2 Way Connector - (CLOCKSPRING) 2 WAY AIRBAG-DRIVER SQUIB 2 - (CLOCKSPRING) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Airbag Squib 1 (Clockspring) 2 Way > Page 7643 Air Bag: Diagrams Passenger Airbag Squib (Instrument Panel) 4 Way Connector - (INSTRUMENT PANEL) 4 WAY AIRBAG-PASSENGER SQUIB - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Airbag Squib 1 (Clockspring) 2 Way > Page 7644 Air Bag: Diagrams Left Side Curtain Airbag (Body) 2 Way Connector - (BODY) 2 WAY AIRBAG-SIDE CURTAIN-LEFT - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Diagrams > Driver Airbag Squib 1 (Clockspring) 2 Way > Page 7645 Air Bag: Diagrams Right Side Curtain Airbag (Body) 2 Way Connector - (BODY) 2 WAY AIRBAG-SIDE CURTAIN-RIGHT - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description Air Bag: Description and Operation Side Curtain Air Bag - Description DESCRIPTION Optional side curtain airbags are available for this vehicle when it is also equipped with dual front airbags. These airbags are passive, inflatable, Supplemental Restraint System (SRS) components, and vehicles with this equipment can be readily identified by a molded identification trim button with the SRS - AIRBAG logo located near the top of each upper B-pillar trim panel. This system is designed to reduce injuries to the vehicle occupants in the event of a side impact collision or a vehicle rollover incident. Vehicles equipped with side curtain airbags have two individually controlled curtain airbag units. These airbag units are concealed and mounted above the headliner where they are each secured to one of the roof side rails. Each folded airbag cushion is contained within a fabric wrap (5) that extends along the roof rail from the A-pillar at the front of the vehicle to the D-pillar at the rear of the vehicle. The airbag unit is initially secured during installation with metal clips and plastic push-in fasteners to the roof rail. A long tether (3) extends down the A-pillar from the front of the airbag cushion, where it is retained to the pillar with plastic push-in routing clips and it is secured to the base of the A-pillar near the belt line with a screw and a rivet nut. A short tether (6) at the rear of the cushion is secured by a screw to a U-nut located near the top of the D-pillar. The hybrid-type inflator (1) for each airbag is secured to the roof rail at the front of the airbag unit between the A-pillar and the B-pillar, and is connected to the airbag cushion by a long tubular manifold (2). The entire assembly is secured to U-nuts spaced along the inside of the roof rail with screws; however, the mounting provisions between the right and left curtain airbag units is asymmetrical by design. A two-wire pigtail harness (4) is routed from the rear of the airbag inflator and down the B-pillar, where it is retained by routing clips. The pigtail harness is connected to a take out and connector of the body wire harness on the B-pillar, which connects the airbag unit to the Occupant Restraint Controller (ORC). The side curtain airbag unit cannot be adjusted or repaired and must be replaced if deployed, ineffective, or in any way damaged. Once a side curtain Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 7648 airbag has been deployed, the complete airbag unit, the headliner, the upper A, B, C and D-pillar trim, and all other visibly damaged components must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 7649 Air Bag: Description and Operation Side Curtain Air Bag - Operation OPERATION Each side curtain airbag is deployed individually by an electrical signal generated by the Occupant Restraint Controller (ORC) to which it is connected through left or right curtain airbag line 1 and line 2 (or squib) circuits. The hybrid-type inflator assembly for each airbag contains a small canister of highly compressed inert gas. When the ORC sends the proper electrical signal to the airbag inflator, the electrical energy creates enough heat to ignite chemical pellets within the inflator. Once ignited, these chemicals burn rapidly and produce the pressure necessary to rupture a containment disk in the inert gas canister. The inflator and inert gas canister are sealed and connected to a tubular manifold so that all of the released gas is directed into the folded curtain airbag cushion, causing the cushion to inflate. As the airbag cushion inflates it will drop down from the roof rail between the edge of the headliner and the side glass/body pillars to form a curtain-like cushion to protect the vehicle occupants during a side impact collision or a vehicle rollover incident. The front and rear tethers keep the side airbag cushion taut to the side of the vehicle, thus ensuring that the bag will deploy in the proper position. Following the airbag deployment, the airbag cushion slowly deflates by venting the inert gas through the loose weave of the cushion fabric, and the deflated cushion hangs down loosely from the roof rail. Proper diagnosis of the side curtain airbag inflator and squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 7650 Air Bag: Description and Operation Driver Air Bag - Description DESCRIPTION The color-keyed, injection molded, thermoplastic driver airbag protective trim cover (2) is the most visible part of the driver airbag. The driver airbag is located in the center of the steering wheel (1), where it is secured with two screws to the armature of the four-spoke steering wheel. All vehicles have either a chrome Dodge Ram or Chrysler emblem in the center of the trim cover. Concealed beneath the driver airbag trim cover are the horn switch, the folded airbag cushion, the airbag cushion retainer, the airbag housing, the airbag inflator, and the retainers that secure the inflator to the airbag housing. The airbag cushion, housing (5), and inflator (3) are secured within an integral receptacle molded into the back of the trim cover (4). The four vertical walls of this receptacle have a total of 12 small windows with blocking tabs that are engaged by 12 hook formations around the perimeter of the airbag housing. Each hook is inserted through one of the windows and the blocking tab in each window keeps the hook properly engaged with the trim cover, locking the trim cover securely into place on the airbag housing. The resistive membrane-type horn switch is secured with heat stakes to the inside surface of the driver airbag trim cover, between the trim cover and the folded airbag cushion. The horn switch ground pigtail wire (2) has an eyelet terminal connector that is captured beneath a flanged nut on the upper right inflator mounting stud on the back of the housing. The horn switch feed pigtail wire has a black, molded plastic insulator (1) that is secured by an integral retainer in a locator hole near the upper right corner of the airbag housing and is connected to the vehicle electrical system through a dedicated take out and connector of the steering wheel wire harness. Both horn switch wires are routed through an integral notch in the center of the upper edge of the airbag housing stamping. The airbag used in this vehicle is a multistage, Next Generation-type that complies with revised federal airbag standards to deploy with less force than those used in some prior vehicles. A 71 centimeter (28 inch) diameter, radial deploying fabric cushion with internal tethers is used. The airbag inflator is a dual-initiator, non-azide, pyrotechnic-type unit with four mounting studs and is secured to the stamped metal airbag housing by four flanged hex nuts. Two keyed and color-coded connector receptacles on the driver airbag inflator connect the two inflator initiators to the vehicle electrical system through two yellow-jacketed, two-wire pigtail harnesses of the clockspring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 7651 The driver airbag unit cannot be repaired, and must be replaced if deployed, ineffective or in any way damaged. The driver airbag trim cover and horn switch unit may be disassembled from the driver airbag unit, and is available for separate service replacement. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 7652 Air Bag: Description and Operation Driver Air Bag - Operation OPERATION The multistage driver airbag is deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the driver airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the monitored impact conditions by providing one of three delay intervals between the electrical signals provided to the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy. When the ORC sends the proper electrical signals to each initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the back of the airbag housing and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the driver airbag trim cover will split at predetermined breakout lines, then fold back out of the way along with the horn switch unit. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas towards the instrument panel through vent holes within the fabric used to construct the back (steering wheel side) panel of the airbag cushion. Some of the chemicals used to create the inert gas may be considered hazardous while in their solid state before they are burned, but they are securely sealed within the airbag inflator. Typically, both initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event. However, it is possible for only one initiator to be used during a deployment due to an airbag system fault; therefore, it is necessary to always confirm that both initiators have been used in order to avoid the improper disposal of potentially live pyrotechnic or hazardous materials. See: Service and Repair. The inert gas that is produced when the chemicals are burned is harmless. However, a small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noted, rinse the affected area with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician. Proper diagnosis of the driver airbag inflator and squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 7653 Air Bag: Description and Operation Side Curtain Air Bag - Description DESCRIPTION Optional side curtain airbags are available for this vehicle when it is also equipped with dual front airbags. These airbags are passive, inflatable, Supplemental Restraint System (SRS) components, and vehicles with this equipment can be readily identified by a molded identification trim button with the SRS - AIRBAG logo located near the top of each upper B-pillar trim panel. This system is designed to reduce injuries to the vehicle occupants in the event of a side impact collision or a vehicle rollover incident. Vehicles equipped with side curtain airbags have two individually controlled curtain airbag units. These airbag units are concealed and mounted above the headliner where they are each secured to one of the roof side rails. Each folded airbag cushion is contained within a fabric wrap (5) that extends along the roof rail from the A-pillar at the front of the vehicle to the D-pillar at the rear of the vehicle. The airbag unit is initially secured during installation with metal clips and plastic push-in fasteners to the roof rail. A long tether (3) extends down the A-pillar from the front of the airbag cushion, where it is retained to the pillar with plastic push-in routing clips and it is secured to the base of the A-pillar near the belt line with a screw and a rivet nut. A short tether (6) at the rear of the cushion is secured by a screw to a U-nut located near the top of the D-pillar. The hybrid-type inflator (1) for each airbag is secured to the roof rail at the front of the airbag unit between the A-pillar and the B-pillar, and is connected to the airbag cushion by a long tubular manifold (2). The entire assembly is secured to U-nuts spaced along the inside of the roof rail with screws; however, the mounting provisions between the right and left curtain airbag units is asymmetrical by design. A two-wire pigtail harness (4) is routed from the rear of the airbag inflator and down the B-pillar, where it is retained by routing clips. The pigtail harness is connected to a take out and connector of the body wire harness on the B-pillar, which connects the airbag unit to the Occupant Restraint Controller (ORC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 7654 The side curtain airbag unit cannot be adjusted or repaired and must be replaced if deployed, ineffective, or in any way damaged. Once a side curtain airbag has been deployed, the complete airbag unit, the headliner, the upper A, B, C and D-pillar trim, and all other visibly damaged components must be replaced. Side Curtain Air Bag - Operation OPERATION Each side curtain airbag is deployed individually by an electrical signal generated by the Occupant Restraint Controller (ORC) to which it is connected through left or right curtain airbag line 1 and line 2 (or squib) circuits. The hybrid-type inflator assembly for each airbag contains a small canister of highly compressed inert gas. When the ORC sends the proper electrical signal to the airbag inflator, the electrical energy creates enough heat to ignite chemical pellets within the inflator. Once ignited, these chemicals burn rapidly and produce the pressure necessary to rupture a containment disk in the inert gas canister. The inflator and inert gas canister are sealed and connected to a tubular manifold so that all of the released gas is directed into the folded curtain airbag cushion, causing the cushion to inflate. As the airbag cushion inflates it will drop down from the roof rail between the edge of the headliner and the side glass/body pillars to form a curtain-like cushion to protect the vehicle occupants during a side impact collision or a vehicle rollover incident. The front and rear tethers keep the side airbag cushion taut to the side of the vehicle, thus ensuring that the bag will deploy in the proper position. Following the airbag deployment, the airbag cushion slowly deflates by venting the inert gas through the loose weave of the cushion fabric, and the deflated cushion hangs down loosely from the roof rail. Proper diagnosis of the side curtain airbag inflator and squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Driver Air Bag - Description DESCRIPTION The color-keyed, injection molded, thermoplastic driver airbag protective trim cover (2) is the most visible part of the driver airbag. The driver airbag is located in the center of the steering wheel (1), where it is secured with two screws to the armature of the four-spoke steering wheel. All vehicles have either a chrome Dodge Ram or Chrysler emblem in the center of the trim cover. Concealed beneath the driver airbag trim cover are the horn switch, the folded airbag cushion, the airbag cushion retainer, the airbag housing, the airbag inflator, and the retainers that secure the inflator to the airbag housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 7655 The airbag cushion, housing (5), and inflator (3) are secured within an integral receptacle molded into the back of the trim cover (4). The four vertical walls of this receptacle have a total of 12 small windows with blocking tabs that are engaged by 12 hook formations around the perimeter of the airbag housing. Each hook is inserted through one of the windows and the blocking tab in each window keeps the hook properly engaged with the trim cover, locking the trim cover securely into place on the airbag housing. The resistive membrane-type horn switch is secured with heat stakes to the inside surface of the driver airbag trim cover, between the trim cover and the folded airbag cushion. The horn switch ground pigtail wire (2) has an eyelet terminal connector that is captured beneath a flanged nut on the upper right inflator mounting stud on the back of the housing. The horn switch feed pigtail wire has a black, molded plastic insulator (1) that is secured by an integral retainer in a locator hole near the upper right corner of the airbag housing and is connected to the vehicle electrical system through a dedicated take out and connector of the steering wheel wire harness. Both horn switch wires are routed through an integral notch in the center of the upper edge of the airbag housing stamping. The airbag used in this vehicle is a multistage, Next Generation-type that complies with revised federal airbag standards to deploy with less force than those used in some prior vehicles. A 71 centimeter (28 inch) diameter, radial deploying fabric cushion with internal tethers is used. The airbag inflator is a dual-initiator, non-azide, pyrotechnic-type unit with four mounting studs and is secured to the stamped metal airbag housing by four flanged hex nuts. Two keyed and color-coded connector receptacles on the driver airbag inflator connect the two inflator initiators to the vehicle electrical system through two yellow-jacketed, two-wire pigtail harnesses of the clockspring. The driver airbag unit cannot be repaired, and must be replaced if deployed, ineffective or in any way damaged. The driver airbag trim cover and horn switch unit may be disassembled from the driver airbag unit, and is available for separate service replacement. Driver Air Bag - Operation OPERATION The multistage driver airbag is deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the driver airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the monitored impact conditions by providing one of three delay intervals between the electrical signals provided to the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy. When the ORC sends the proper electrical signals to each initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the back of the airbag housing and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the driver airbag trim cover will split at predetermined breakout lines, then fold back out of the way along with the horn switch unit. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas towards the instrument panel through vent holes within the fabric used to construct the back (steering wheel side) panel of the airbag cushion. Some of the chemicals used to create the inert gas may be considered hazardous while in their solid state before they are burned, but they are securely sealed within the airbag inflator. Typically, both initiators are used and all potentially hazardous chemicals are burned during an airbag deployment event. However, it is possible for only one initiator to be used during a deployment due to an airbag system fault; therefore, it is necessary to always confirm that both initiators have been used in order to avoid the improper disposal of potentially live pyrotechnic or hazardous materials. See: Service and Repair. The inert gas that is produced when the chemicals are burned is harmless. However, a small amount of residue from the burned chemicals may cause some temporary discomfort if it contacts the skin, eyes, or breathing passages. If skin or eye irritation is noted, rinse the affected area with plenty of cool, clean water. If breathing passages are irritated, move to another area where there is plenty of clean, fresh air to breath. If the irritation is not alleviated by these actions, contact a physician. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 7656 Proper diagnosis of the driver airbag inflator and squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Passenger Air Bag - Description DESCRIPTION The horizontal surface of the injection molded, thermoplastic passenger airbag door (1) is the most visible part of the passenger airbag. The passenger airbag door is located above the glove box opening on the top of the instrument panel (2) in front of the front seat passenger seating position. The outboard edges of the airbag door are secured with integral snap features (3) to the instrument panel base trim. Located below the passenger airbag door (2) within the instrument panel is the passenger airbag unit. The passenger airbag housing fits into a molded receptacle on the back of the airbag door, where twelve stamped hook formations on the forward and rearward edges of the airbag housing are engaged in mating small window openings on the forward and rearward flanges of the receptacle to secure the airbag door to the airbag housing. These airbag door fasteners and mounting provisions are all concealed beneath the instrument panel base trim. The passenger airbag unit is secured by two screws through a stamped mounting bracket (5) to the instrument panel structural support. The passenger airbag unit used in this vehicle is a multistage, Next Generation-type that complies with revised federal airbag standards to deploy with less force than those used in some prior vehicles. The passenger airbag unit consists of a stamped and welded metal housing, the airbag cushion, the airbag inflator, and a stamped metal airbag cushion retainer plate that is secured to the airbag housing with four studs and nuts. The airbag housing contains the airbag inflator and the folded airbag cushion. An approximately 80 centimeter (31.5 inch) wide by 90 centimeter (35.5 inch) high rectangular fabric cushion is used. The airbag inflator (4) is a non-azide, pyrotechnic-type unit that is secured to and sealed within the airbag housing. A short four-wire pigtail harness with a keyed, yellow connector insulator (1) connects the two inflator initiators to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The passenger airbag includes the airbag door. This unit cannot be repaired, and must be replaced if deployed, ineffective, or in any way damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Description and Operation > Side Curtain Air Bag - Description > Page 7657 Passenger Air Bag - Operation OPERATION The multistage passenger airbag is deployed by electrical signals generated by the Occupant Restraint Controller (ORC) through the passenger airbag squib 1 and squib 2 circuits to the two initiators in the airbag inflator. By using two initiators, the airbag can be deployed at multiple levels of force. The force level is controlled by the ORC to suit the monitored impact conditions by providing one of three delay intervals between the electrical signals provided to the two initiators. The longer the delay between these signals, the less forcefully the airbag will deploy. When the ORC sends the proper electrical signals to each initiator, the electrical energy generates enough heat to initiate a small pyrotechnic charge which, in turn ignites chemical pellets within the inflator. Once ignited, these chemical pellets burn rapidly and produce a large quantity of inert gas. The inflator is sealed to the airbag cushion and a diffuser in the inflator directs all of the inert gas into the airbag cushion, causing the cushion to inflate. As the cushion inflates, the passenger airbag door will split at predetermined tear seam lines concealed on the inside surface of the door, then the door will pivot up over the top of the instrument panel and out of the way. Following an airbag deployment, the airbag cushion quickly deflates by venting the inert gas through a vent hole in each fabric side panel of the airbag cushion. Typically, both initiators are used during an airbag deployment event. However, it is possible for only one initiator to be used during a deployment due to an airbag system fault; therefore, it is necessary to always confirm that both initiators have been used in order to avoid the improper disposal of potentially live pyrotechnic materials. See: Service and Repair. Proper diagnosis of the passenger airbag inflator and the passenger airbag squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement Air Bag: Removal and Replacement Side Curtain Air Bag - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the side curtain airbag, or becoming entrapped between the side curtain airbag cushion and the headliner. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged side curtain airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the side curtain airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . NOTE: The graphic that accompanies this procedure represents a left side installation. While the right side installation is similar, the mounting hardware quantities and locations for these two units is asymmetrical. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. Remove the headliner from the vehicle. See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Removal. 3. Remove the lower trim from the inside of the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. 4. Disconnect the side curtain airbag pigtail wire connector (3) from the body wire harness connector (2) on the lower inner B-pillar. 5. Disengage the pigtail wire plastic retainers from the inner B-pillar. 6. Remove the screw that secures the side curtain airbag (4) front tether to the rivet nut in the inner A-pillar near the belt line. 7. Remove the eight screws that secure the side curtain airbag to the U-nuts in the inner roof rail and D-pillar. 8. Disengage the two plastic retainers that secure the airbag front tether to the inner A-pillar. 9. For the right side airbag only, disengage the plastic retainer from the inner roof side rail above the quarter window. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 7660 CAUTION: The weight of a non-deployed side curtain airbag inflator (1) must always be fully supported during unit removal or installation. 10. Disengage the metal clips (two on right side airbag, four on left side airbag) that secure the unit to the inner roof rail. 11. Remove the side curtain airbag from the vehicle through the rear door opening as a unit. Side Curtain Air Bag - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the side curtain airbag, or becoming entrapped between the side curtain airbag cushion and the headliner. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged side curtain airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the side curtain airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . 1. Check to be certain that the rivet nut (2) is properly installed in the inner A-pillar, and that it is in good condition. 2. Check to be certain that the eight U-nuts (3) are properly installed in the inner roof rail (1) and inner D-pillar, and that they are in good condition. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 7661 NOTE: The graphic that accompanies this procedure represents a left side installation. While the right side installation is similar, the mounting hardware quantities and locations for these two units is asymmetrical. CAUTION: The weight of a non-deployed side curtain airbag inflator (1) must always be fully supported during unit removal or installation. 3. Position the side curtain airbag (4) into the vehicle as a unit through the rear door opening. The weight of the side curtain airbag inflator (1) must always be fully supported during unit installation. 4. Engage the metal clips (two on right side airbag, four on left side airbag) that secure the unit to the inner roof rail. 5. For the right side airbag only, engage the plastic retainer to the inner roof side rail above the quarter window. 6. Engage the two plastic retainers that secure the airbag front tether to the inner A-pillar. 7. Install and tighten the eight screws that secure the side curtain airbag to the U-nuts in the inner roof rail and D-pillar. Tighten the screws to 10 Nm (90 in. lbs.). 8. Install and tighten the screw that secures the side curtain airbag front tether to the rivet nut in the inner A-pillar near the belt line. Tighten the screw to 6 Nm (50 in. lbs.). 9. Reconnect the side curtain airbag pigtail wire connector (3) to the body wire harness connector (2) on the lower inner B-pillar. Be certain the connector latches are fully engaged. 10. Engage the pigtail wire plastic retainers with their holes in the inner B-pillar. 11. Reinstall the lower trim onto the inside of the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. 12. Reinstall the headliner into the vehicle. See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. Driver Air Bag - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag cushion and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 7662 NOTE: The following procedure is for replacement of an ineffective or damaged driver airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the driver airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. From the underside of the steering wheel, remove the two screws (3) that secure the driver airbag (1) to the steering wheel armature (2). CAUTION: Do not pull on the horn switch feed pigtail wire to disengage the connector from the driver airbag housing or to disconnect the horn switch to steering wheel wire harness connection. Improper pulling on this pigtail wire or connection can result in damage to the horn switch membrane or feed circuit. 3. Pull the driver airbag (1) away from the steering wheel far enough to access the three electrical connections on the back of the airbag housing. 4. Disconnect the steering wheel wire harness connector for the horn switch (2) from the horn switch feed pigtail wire connector (4), which is located on the back of the driver airbag housing. CAUTION: Do not pull on the clockspring pigtail wires or pry on the connector insulator to disengage the connector from the driver airbag inflator connector receptacle. Improper removal of these pigtail wires and their connector insulators can result in damage to the airbag circuits or connector insulators. 5. The clockspring driver airbag pigtail wire connectors (3) are secured by integral latches to the airbag inflator connector receptacles, which are located on the back of the driver airbag housing. Depress the latches on each side of the connector insulator and pull the insulators straight out from the airbag inflator to disconnect them from the connector receptacles. 6. Remove the driver airbag from the steering wheel. 7. If the driver airbag has been deployed, the clockspring must be replaced and the steering column must be inspected. See: Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement/Clockspring - Removal. See: Steering and Suspension/Steering/Steering Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 7663 Column/Testing and Inspection. Driver Air Bag - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the driver airbag, or becoming entrapped between the driver airbag cushion and the driver airbag trim cover. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the driver airbag trim cover must never be painted. Replacement airbags are serviced with trim covers in the original colors. Paint may change the way in which the material of the trim cover responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged driver airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the driver airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . 1. Position the driver airbag (1) close enough to the steering wheel to reconnect the three electrical connections on the back of the airbag housing. 2. When installing the driver airbag, reconnect the two clockspring driver airbag pigtail wire connectors (3) to the airbag inflator connector receptacles by pressing straight in on the connector. Be certain to engage each keyed and color-coded connector to the matching connector receptacle. You can be certain that each connector is fully engaged in its receptacle by listening carefully for a distinct, audible click as the connector latches snap into place. 3. Reconnect the steering wheel wire harness connector (2) for the horn switch to the horn switch feed pigtail wire connector (4), which is located on the back of the driver airbag housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 7664 4. Carefully position the driver airbag (1) in the steering wheel (2). Be certain that the clockspring pigtail wires and the steering wheel wire harness in the steering wheel hub area are not pinched between the driver airbag and the steering wheel armature. 5. From the underside of the steering wheel, install and tighten the two screws (3) that secure the driver airbag to the steering wheel armature. Tighten the screws to 10 Nm (90 in. lbs.). WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. Passenger Air Bag - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury when removing a deployed airbag, rubber gloves, eye protection, and a long-sleeved shirt should be worn. There may be deposits on the airbag unit and other interior surfaces. In large doses, these deposits may cause irritation to the skin and eyes. NOTE: The following procedure is for replacement of an ineffective or damaged passenger airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the passenger airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . CAUTION: Be certain to take the proper precautions to prevent the instrument panel top pad from receiving cosmetic damage from the passenger airbag housing during the following procedures. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 7665 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. Remove the defroster grille from the top of the instrument panel. See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille - Removal. 3. Remove the glove box from the instrument panel. 4. Reach up into the instrument panel glove box opening (2) and through the access holes (1) to remove the two screws (4) that secure the passenger airbag bracket (3) to the instrument panel support structure. 5. Using a trim stick or another suitable wide flat-bladed tool, gently pry the forward and side edges of the passenger airbag door away from the top of the instrument panel far enough to disengage the snap features on the door from the receptacles in the instrument panel top pad. 6. Pull the passenger airbag out of the instrument panel far enough to access and disconnect the instrument panel wire harness connector from the airbag inflator pigtail wire connector on the right side of the airbag mounting bracket. To disconnect the connector: a. Slide the red Connector Position Assurance (CPA) lock on the top of the connector toward the side of the connector. b. Depress the connector latch tab and pull the two halves of the connector straight away from each other. 7. Remove the passenger airbag from the instrument panel as a unit. Passenger Air Bag - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the passenger airbag, or becoming entrapped between the passenger airbag cushion and the passenger airbag door. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the passenger airbag door must never be painted. Replacement passenger airbags are serviced with doors in the original colors. Paint may change the way in which the material of the airbag door responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedure is for replacement of an ineffective or damaged passenger airbag. If the airbag is ineffective or damaged, but not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the passenger airbag has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the airbag from the vehicle. See: Service and Repair . Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 7666 CAUTION: Be certain to take the proper precautions to prevent the instrument panel top pad from receiving cosmetic damage from the passenger airbag housing during the following procedures. 1. Position the passenger airbag unit onto the instrument panel. 2. Reconnect the instrument panel wire harness connector for the airbag to the passenger airbag inflator pigtail wire connector on the right side of the airbag mounting bracket. Be certain that the latch on the connector and the red Connector Position Assurance (CPA) lock are each fully engaged. 3. Carefully lower the passenger airbag unit into the instrument panel, being certain that the airbag mounting bracket (3) is properly positioned to the instrument panel support structure. 4. Reach into the glove box opening (2) to install and tighten the two screws (4) that secure the passenger airbag mounting bracket to the instrument panel support structure through the access holes (1). Tighten the screws to 6 Nm (55 in. lbs.). 5. Align and insert the rearward tabs of the passenger airbag door into the slots in the instrument panel top pad. 6. Using hand pressure, push down on the forward and side edges of the passenger airbag door over each snap feature until it snaps into its receptacle in the instrument panel top pad. 7. Reinstall the glove box into the instrument panel. 8. Reinstall the defroster grille onto the top of the instrument panel. See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille - Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 7667 Air Bag: Overhaul Driver Air Bag - Disassembly DISASSEMBLY WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, service of this unit should be performed only by Chrysler-trained and authorized dealer service technicians. Failure to take the proper precautions or to follow the proper procedures could result in accidental, incomplete, or improper airbag deployment and possible occupant injuries. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the driver airbag, or becoming entrapped between the driver airbag cushion and the driver airbag trim cover. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the driver airbag trim cover must never be painted. Replacement trim covers are serviced in the original colors. Paint may change the way in which the material of the trim cover responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedures can be used to replace the driver airbag trim cover and horn switch unit for service. If the driver airbag is ineffective or deployed, the entire driver airbag, trim cover and horn switch must be replaced as a unit. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. Remove the driver airbag from the steering wheel See: Removal and Replacement/Driver Air Bag - Removal. 3. Place the driver airbag on a suitable clean and dry work surface with the trim cover facing down. If the trim cover will be reused, be certain to take the proper precautions to prevent the trim cover from receiving cosmetic damage during the following procedures. 4. Carefully pry the horn switch feed pigtail wire connector (1) away from the back of the driver airbag housing (3) far enough to disengage the integral connector retainer from the locator hole just above the upper right inflator mounting stud. 5. Remove the nut that secures the horn switch ground pigtail wire eyelet terminal (2) to the upper right inflator stud on the back of the driver airbag housing. 6. Remove the horn switch ground pigtail wire eyelet terminal from the upper right inflator stud on the back of the driver airbag housing. 7. Disengage each of the twelve hooks (5 and 6) of the airbag housing from the twelve windows in the vertical walls of the trim cover (4), one wall at a time. Start by disengaging the upper wall, then do each of the two side walls, and finish with the lower wall. To disengage the hooks, use hand pressure to push the adjacent edge of the airbag housing firmly and evenly downward into the trim cover receptacle, while at the same time pushing outward on the upper edge of the receptacle wall. 8. With all of the hooks disengaged, lift the housing, inflator, and cushion as a unit from the receptacle on the back of the driver airbag trim cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 7668 Driver Air Bag - Assembly ASSEMBLY WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, service of this unit should be performed only by Chrysler-trained and authorized dealer service technicians. Failure to take the proper precautions or to follow the proper procedures could result in accidental, incomplete, or improper airbag deployment and possible occupant injuries. WARNING: To avoid serious or fatal injury, use extreme care to prevent any foreign material from entering the driver airbag, or becoming entrapped between the driver airbag cushion and the driver airbag trim cover. Failure to observe this warning could result in occupant injuries upon airbag deployment. WARNING: To avoid serious or fatal injury, the driver airbag trim cover must never be painted. Replacement trim covers are serviced in the original colors. Paint may change the way in which the material of the trim cover responds to an airbag deployment. Failure to observe this warning could result in occupant injuries upon airbag deployment. NOTE: The following procedures can be used to replace the driver airbag trim cover and horn switch unit for service. If the driver airbag is ineffective or deployed, the entire driver airbag, trim cover and horn switch must be replaced as a unit. 1. Place the driver airbag on a suitable work surface with the airbag cushion facing up. 2. Fold the two flaps (1) of cushion material up around the sides and over the top of the airbag cushion retainer strap (2). 3. Position the new driver airbag trim cover over the airbag cushion, then push the receptacle of the trim cover down evenly over the cushion. Be certain that the cushion material flaps remain oriented over the cushion retainer strap as they were in 2. 4. Turn the driver airbag and the new driver airbag trim cover over as a unit, and place the unit on a suitable clean and dry work surface with the airbag cushion facing down. Be certain to take the proper precautions to prevent the trim cover from receiving cosmetic damage during the following procedures. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Removal and Replacement > Page 7669 5. Be certain that the horn switch feed and ground pigtail wires are routed through the clearance notch at the top of the airbag housing (3), between the housing and the upper vertical wall of the trim cover receptacle. 6. Work around the perimeter of the unit engaging each of the twelve hooks (5 and 6) on the driver airbag housing through the windows in the walls of the trim cover receptacle. 7. Install the horn switch ground pigtail wire eyelet terminal (2) over the upper right inflator stud on the back of the driver airbag housing. 8. Install and tighten the nut that secures the horn switch ground pigtail wire eyelet terminal to the upper right inflator stud on the back of the driver airbag housing. Tighten the nut to 7 Nm (65 in. lbs.). 9. Using hand pressure, push the integral retainer of the horn switch feed pigtail wire connector (1) into the locator hole just above the upper right inflator mounting stud on the back of the airbag housing. 10. After the driver airbag has been assembled, try pulling the trim cover and the airbag housing away from each other. This action will fully seat the edges of the windows into the cradles of the hooks. 11. Before reinstalling the airbag onto the steering wheel, check that the blocking tab (1) in each of the trim cover windows is oriented over the airbag housing hook (4) as shown. 12. Reinstall the driver airbag onto the steering wheel See: Removal and Replacement/Driver Air Bag - Installation. WARNING: DO NOT CONNECT THE BATTERY NEGATIVE CABLE. PERSONAL INJURY OR DEATH MAY RESULT IF THE SYSTEM TEST IS NOT PERFORMED FIRST. FOR THE SYSTEM TEST, See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Supplemental Restraints Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Locations > Page 7673 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 32 Way Air Bag Control Module: Diagrams Occupant Restraint Controller Module C1 (Body) 32 Way Connector C1 - (BODY) 32 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (BODY) 32 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 32 Way > Page 7676 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 32 Way > Page 7677 Air Bag Control Module: Diagrams Occupant Restraint Controller Module C2 (Side AIRBAG) 24 Way Connector C2 - (SIDE AIRBAG) 24 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (SIDE AIRBAG) 24 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description Air Bag Control Module: Description and Operation Occupant Restraint Controller - Description DESCRIPTION The Occupant Restraint Controller (ORC) (1) is secured with three screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel just behind the front seat crossmember and beneath the center floor console in the passenger compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow (3) printed on the label (2) on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges on three corners. The mounting flange to the right of the connector receptacle has an integral locating pin on its lower surface. Both right side flanges have round mounting holes, while the flange on the left side has a slotted mounting hole. A molded plastic electrical connector (4) with 2 receptacles, one containing 24 terminal pins and the other containing 32 terminal pins, exits the forward facing side of the ORC housing. These terminal pins connect the ORC to the vehicle electrical system through two dedicated take outs and connectors of the body wire harness. The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without the optional side curtain airbags. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description > Page 7680 Air Bag Control Module: Description and Operation Occupant Restraint Controller - Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC) contains the Supplemental Restraint System (SRS) logic circuits and controls all of the SRS components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and for SRS diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. See: Malfunction Lamp / Indicator/Description and Operation/Air Bag Indicator - Operation. The ORC microprocessor continuously monitors all of the SRS electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. The ORC receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Junction Block (JB), and a fused ignition switch output (run-start) circuit through a second fuse in the JB. The ORC receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw near the center of the instrument panel structural support. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the SRS components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup SRS protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from two remote front impact sensors located on the back of the right and left vertical members of the radiator support near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The ORC also monitors inputs from an internal rollover sensor and six additional remote impact sensors located on the left and right inner B-pillars and quarter inner panels to control deployment of the side curtain airbag units. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a SRS component deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. A second safing sensor within the ORC provides confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require SRS protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and either side curtain airbag unit. The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls or communication between other modules and devices that provide features of the SRS. The most reliable, efficient, and accurate means to diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal Air Bag Control Module: Service and Repair Occupant Restraint Controller - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side SRS components in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side SRS components will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the Supplemental Restraint System (SRS) components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. Remove the center console from the top of the floor panel transmission tunnel. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Removal. 3. Disconnect the two body wire harness connectors (1) from the Occupant Restraint Controller (ORC) (2) connector receptacles located on the forward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm on each connector. 4. Remove the three screws (3) that secure the ORC to the ORC bracket (4) that is welded onto the top of the floor panel transmission tunnel. 5. Remove the ORC from the floor panel transmission tunnel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal > Page 7683 Air Bag Control Module: Service and Repair Occupant Restraint Controller - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side SRS components in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side SRS components will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the Supplemental Restraint System (SRS) components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. 1. Carefully position the Occupant Restraint Controller (ORC) (2) to the ORC bracket (4) on the floor panel transmission tunnel. When the ORC is correctly positioned, the arrow on the ORC label will be pointed forward in the vehicle and the locating pin on the bottom of the right ORC mounting flange will be engaged into the locating hole in the ORC bracket. 2. Install and tighten the three screws (3) that secure the ORC to the ORC bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 11 Nm (8 ft. lbs.). CAUTION: The lever arms of the wire harness connectors for the ORC MUST be in the unlatched position before they are inserted into their connector receptacles on the ORC or they may become damaged. 3. Reconnect the two body wire harness connectors (1) to the ORC connector receptacles located on the forward facing side of the module. Be certain that the latches on both connectors are each fully engaged. 4. Reinstall the center console onto the top of the floor panel transmission tunnel. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Installation. 5. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations Clockspring Assembly / Spiral Cable: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Locations > Page 7687 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Clockspring C1 (Instrument Panel) 6 Way Clockspring Assembly / Spiral Cable: Diagrams Clockspring C1 (Instrument Panel) 6 Way Connector C1 - (INSTRUMENT PANEL) 6 WAY CLOCKSPRING - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Clockspring C1 (Instrument Panel) 6 Way > Page 7690 Clockspring Assembly / Spiral Cable: Diagrams Clockspring C2 (Instrument Panel) 4 Way Connector C2 - (INSTRUMENT PANEL) 4 WAY CLOCKSPRING - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Clockspring C1 (Instrument Panel) 6 Way > Page 7691 Clockspring Assembly / Spiral Cable: Diagrams Clockspring C3 4 Way Connector C3 - 4 WAY CLOCKSPRING - 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Clockspring C1 (Instrument Panel) 6 Way > Page 7692 Clockspring Assembly / Spiral Cable: Diagrams Clockspring C4 (Steering Wheel) 2 Way Connector C4 - (STEERING WHEEL) 2 WAY CLOCKSPRING - (STEERING WHEEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Clockspring - Description Clockspring Assembly / Spiral Cable: Description and Operation Clockspring - Description DESCRIPTION The clockspring assembly is located near the top of the steering column behind the steering wheel. Two mounting tabs (6) with round holes integral to the sides of the case are secured by two screws onto the multi-function switch mounting housing. The clockspring for this vehicle also includes an integral, internal Steering Angle Sensor (SAS) for the Electronic Stability Program (ESP) that is serviced as a unit with the clockspring. The clockspring consists of a flat, round molded plastic case (4) with a stubby tail that hangs below the steering column. Within the plastic case is a spool-like molded plastic rotor with a large exposed hub. The upper surface of the rotor hub has a large center hole, an engagement dowel (5), two short pigtail wires with connectors (1), and two connector receptacles (3) that face toward the steering wheel. Service replacement clocksprings are shipped pre-centered and with a molded plastic locking pin (2) that snaps into a receptacle on the rotor and is engaged with tabs on the upper surface of the clockspring case. The locking pin secures the centered clockspring rotor to the clockspring case during shipment and handling, but must be removed from the clockspring after it is installed on the steering column. See: Service and Repair/Procedures. The lower surface of the case (1) facing toward the instrument panel includes a locating tab (2) that is engaged by a locating pin on the multi-function switch mounting housing, two integral connector receptacles (5) and an additional applied connector (4) with a short pigtail wire on the lower end, outboard of the two integral connector receptacles. The lower surface of the rotor hub also has a molded plastic turn signal cancel cam with two lobes (3) that is integral to the rotor. Within the plastic case and wound around the rotor spool is a long ribbon-like tape that consists of several thin copper wire leads sandwiched between two thin plastic membranes. The outer end of the tape terminates at the connector receptacles that face the instrument panel, while the inner end of the tape terminates at the pigtail wires and connector receptacles on the hub of the clockspring rotor that face the steering wheel. The clockspring cannot be repaired. If damaged, ineffective or if the driver airbag has been deployed, the clockspring must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Description and Operation > Clockspring - Description > Page 7695 Clockspring Assembly / Spiral Cable: Description and Operation Clockspring - Operation OPERATION The clockspring is a mechanical electrical circuit component that is used to provide continuous electrical continuity between the fixed instrument panel wire harness and the electrical components mounted on or in the rotating steering wheel. On this vehicle the rotating electrical components include the driver airbag, the horn switch, the speed control switches, and the remote radio switches, if the vehicle is so equipped. The clockspring case is positioned and secured to the multi-function switch mounting housing near the top of the steering column. The connector receptacles on the tail of the fixed clockspring case connect the clockspring to the vehicle electrical system through two take outs with connectors from the instrument panel wire harness. The clockspring rotor is movable and is keyed by an engagement dowel that is molded onto the rotor hub between two fins that are cast into the lower surface of the steering wheel armature. A yellow rubber boot is installed over the engagement dowel to eliminate contact noise between the dowel and the steering wheel. The two lobes on the turn signal cancel cam on the lower surface of the clockspring rotor hub contact a turn signal cancel actuator of the multi-function switch to provide automatic turn signal cancellation. Two short, yellow-sleeved pigtail wires on the upper surface of the clockspring rotor connect the clockspring to the multistage driver airbag, while a steering wheel wire harness connects the two connector receptacles on the upper surface of the clockspring rotor to the horn switch feed pigtail wire connector and, if the vehicle is so equipped, to the optional speed control and remote radio switches on the steering wheel. Like the clockspring in a timepiece, the clockspring tape has travel limits and can be damaged by being wound too tightly during full stop-to-stop steering wheel rotation. To prevent this from occurring, the clockspring is centered when it is installed on the steering column. Centering the clockspring indexes the clockspring tape to the movable steering components so that the tape can operate within its designed travel limits. However, if the clockspring is removed from the steering column or if the steering shaft is disconnected from the steering gear, the clockspring spool can change position relative to the movable steering components. The clockspring must be re-centered following completion of this service or the tape may be damaged. Service replacement clocksprings are shipped pre-centered and with a plastic locking pin installed. This locking pin should not be removed until the clockspring has been installed on the steering column. If the locking pin is removed before the clockspring is installed on a steering column, the clockspring centering procedure must be performed. See: Service and Repair/Procedures. The clockspring as well as the hard wired inputs and outputs of the clockspring may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, on vehicles equipped with Electronic Stability Program (ESP) conventional diagnostic methods will not prove conclusive in the diagnosis of the Steering Angle Sensor (SAS) within the clockspring or the electronic controls or communication between other modules and devices that provide features of the ESP. The most reliable, efficient, and accurate means to diagnose the SAS or the electronic controls and communication related to ESP operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures Clockspring Assembly / Spiral Cable: Procedures CLOCKSPRING CENTERING WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight-ahead position. 2. Remove the clockspring from the steering column. See: Removal and Replacement/Clockspring - Removal. 3. Rotate the clockspring rotor (7) clockwise to the end of its travel. Do not apply excessive torque. 4. From the end of the clockwise travel, rotate the rotor about two and one-half turns counterclockwise. The engagement dowel (5) should end up at the bottom, and the airbag pigtail wires (1) and connector receptacles (3) should be at the top. Turn the rotor slightly clockwise or counterclockwise as necessary so that the slots for the clockspring locking pin (2) are in alignment. 5. The clockspring is now centered. Secure the clockspring rotor to the clockspring case to maintain clockspring centering until it is reinstalled on the steering column. 6. The front wheels should still be in the straight-ahead position. Reinstall the clockspring onto the steering column. See: Removal and Replacement/Clockspring - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 7698 Clockspring Assembly / Spiral Cable: Removal and Replacement Clockspring - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: Before starting this procedure, be certain to turn the steering wheel until the front wheels are in the straight-ahead position. 1. Place the front wheels in the straight ahead position. 2. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 3. Remove the driver airbag from the steering wheel. See: Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag - Removal. 4. Disconnect the steering wheel wire harness connectors from the upper clockspring connector receptacles. CAUTION: Be certain that the screws that secure the steering wheel puller to the steering wheel are fully engaged in the steering wheel armature without passing through the steering wheel and damaging the clockspring. 5. Remove the steering wheel from the steering column. See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Removal. 6. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 7699 7. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 8. Using hand pressure, push gently inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 9. Remove the upper shroud from the lower shroud and the steering column. 10. Remove the one center screw that secures the lower shroud to the steering column (4). 11. Remove the lower shroud from the steering column. 12. Disconnect the two instrument panel wire harness connectors from the two connector receptacles located below the steering column on the back of the clockspring housing. 13. Disconnect the instrument panel wire harness connector from the applied connector for the Steering Angle Sensor (SAS) located below the steering column on the back of the clockspring housing. 14. Remove the two screws (2) that secure the clockspring (4) to the multi-function switch mounting housing on the steering column (3). 15. Remove the clockspring from the multi-function switch mounting housing. The clockspring cannot be repaired. It must be replaced if ineffective or damaged, or if the driver airbag has been deployed. 16. If the removed clockspring is to be reused, be certain to secure the clockspring rotor to the clockspring case to maintain clockspring centering until it is reinstalled on the steering column. If clockspring centering is not maintained, the clockspring must be centered again before it is reinstalled. See: Procedures. Clockspring - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 7700 CAUTION: If the clockspring is not properly centered in relation to the Steering Angle Sensor (SAS), steering wheel, steering shaft and steering gear, it may be damaged or Diagnostic Trouble Codes (DTC) may be set in the SAS. See: Procedures . Service replacement clocksprings are shipped pre-centered and with a locking pin installed. This locking pin should not be removed until the clockspring has been installed on the steering column. NOTE: Before starting this procedure, be certain that the front wheels are still in the straight-ahead position. 1. While holding the centered clockspring rotor and case stationary in relation to each other, or with the plastic locking pin (1) installed, carefully slide the clockspring (4) down over the steering column (3) upper shaft. 2. Align and seat the hole in the locating tab on the clockspring case over the locating pin on the multi-function switch mounting housing. 3. Install and tighten the two screws (2) that secure the clockspring to the multi-function switch mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 4. Reconnect the two instrument panel wire harness connectors to the two connector receptacles located below the steering column on the back of the clockspring housing. 5. Reconnect the instrument panel wire harness connector to the applied connector for the Steering Angle Sensor (SAS) located below the steering column on the back of the clockspring housing. 6. Position the lower shroud (3) onto the steering column (4). 7. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 8. Position the upper shroud (1) onto the steering column over the lower shroud. Be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 9. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 10. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Service and Repair > Procedures > Page 7701 11. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 12. If a new clockspring has been installed, remove the plastic locking pin that is securing the clockspring rotor to the clockspring case to maintain clockspring centering. NOTE: When reinstalling the steering wheel, be certain to index the engagement dowel on the upper surface of the clockspring rotor between the two fins cast into the lower surface of the steering wheel armature hub. 13. Reinstall the steering wheel onto the steering column. See: Steering and Suspension/Steering/Steering Wheel/Service and Repair/Installation. 14. Reconnect the steering wheel wire harness connectors to the upper clockspring connector receptacles. Be certain that the steering wheel wire harness is routed between the steering wheel back trim cover and the steering wheel armature. 15. Reinstall the driver airbag onto the steering wheel. See: Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag - Installation. 16. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7706 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7707 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7708 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7709 Impact Sensor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7710 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7711 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7712 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7713 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7714 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way Impact Sensor: Diagrams Left Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 1 - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 7717 Impact Sensor: Diagrams Left Side Impact Sensor 2 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 2 - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 7718 Impact Sensor: Diagrams Right Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-RIGHT 1 - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 7719 Impact Sensor: Diagrams Left Front Impact Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-FRONT IMPACT-LEFT - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 7720 Impact Sensor: Diagrams Left Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 1 - (BODY) 4 WAY Left Side Impact Sensor 2 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 2 - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 7721 Right Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-RIGHT 1 - (BODY) 4 WAY Left Front Impact Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 7722 SENSOR-FRONT IMPACT-LEFT - (HEADLAMP AND DASH) 2 WAY Right Front Impact Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-FRONT IMPACT-RIGHT - (HEADLAMP AND DASH) 2 WAY Right Side Impact Sensor 2 (Body) 4 Way Connector - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 7723 SENSOR-SIDE IMPACT-RIGHT 2 - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description Impact Sensor: Description and Operation Impact Sensor - Description Front FRONT Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front sensor is secured with a screw to the backs of the right and left vertical members of the radiator support within the engine compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side SIDE Four side impact sensors (1) are used on this vehicle to support the standard side curtain airbags, two each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the right or left B-pillar and quarter inner panel within the passenger compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 7726 The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 7727 Impact Sensor: Description and Operation Impact Sensor - Operation Front FRONT The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the front impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side SIDE The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through the same left or right sensor plus and minus circuits in a series arrangement from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal Impact Sensor: Service and Repair Impact Sensor - Removal Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. Remove the screw (3) that secures the right or left front impact sensor (1) to the back of the right or left radiator support vertical member (2). 3. Disconnect the headlamp and dash wire harness connector (4) from the sensor connector receptacle. 4. Remove the right or left front impact sensor from the engine compartment. Side - B-Pillar SIDE - B-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7730 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 3. Remove the lower trim from the inside of the right or left B-pillar (1). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. 4. Remove the screw (4) that secures the side impact sensor (3) to the lower B-pillar. 5. Disconnect the body wire harness connector (2) from the sensor connector receptacle. 6. Remove the sensor from the B-pillar. Side - C/D-Pillar SIDE - C/D-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7731 two minutes for the system capacitors to discharge before further service. 2. Remove the quarter trim panel from the quarter inner panel near the lower C-pillar (5). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Remove the screw (1) that secures the side impact sensor (2) to the quarter inner panel. 4. Disconnect the body wire harness (4) connector from the sensor connector receptacle. 5. Remove the sensor from the quarter inner panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7732 Impact Sensor: Service and Repair Impact Sensor - Installation Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. 1. Position the right or left front impact sensor (1) into the engine compartment. 2. Reconnect the headlamp and dash wire harness connector (4) to the sensor connector receptacle. 3. Position the sensor onto the back of the right or left radiator support vertical member (2). Be certain that the anti-rotation pin on the back of the sensor is engaged in the lower clearance hole of the radiator support. 4. Install and tighten the screw (3) that secures the sensor to the back of the support vertical member. Tighten the screw to 6 Nm (55 in. lbs.). 5. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Side - B-Pillar SIDE - B-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7733 1. Check to be certain that the rivet nut used to secure the side impact sensor (3) is properly installed in the inner B-pillar (1),and that it is in good condition. 2. Position the side impact sensor near the inner B-pillar. 3. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 4. Position the sensor onto the inner B-pillar. Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole (5) of the B-pillar. 5. Install and tighten the screw (4) that secures the sensor to the inner B-pillar. Tighten the screw to 6 Nm (50 in. lbs.). 6. Reinstall the lower trim onto the inside of the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. 7. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Side - C/D-Pillar SIDE - C/D-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7734 1. Check to be certain that the rivet nut (3) used to secure the side impact sensor (2) is properly installed in the quarter inner panel, and that it is in good condition. 2. Position the side impact sensor near the quarter inner panel. 3. Reconnect the body wire harness (4) connector to the sensor connector receptacle. 4. Position the sensor onto the quarter inner panel. Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the quarter inner panel. 5. Install and tighten the screw (1) that secures the sensor to the quarter inner panel. Tighten the screw to 6 Nm (50 in. lbs.). 6. Reinstall the quarter trim panel onto the quarter inner panel near the lower C-pillar (5). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 7. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description Seat Position Sensor: Description and Operation Seat Track Position Sensor - Description DESCRIPTION The seat track position sensor (1) is a Hall Effect-type sensor. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has two integral snap features (3) and snaps into a stamped metal bracket located on the inboard side of one of the seat adjuster tracks on the front seat of vehicles so equipped. A molded connector receptacle (2) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if ineffective or damaged, the entire sensor must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description > Page 7739 Seat Position Sensor: Description and Operation Seat Track Position Sensor - Operation OPERATION The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver side front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver side front airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected. The ORC then sends messages over the Controller Area Network (CAN) data bus to control the illumination of the airbag indicator in the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The hard wired circuits between the seat track position sensor and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the seat track position sensor or the electronic controls and communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the seat track position sensor or the electronic controls and communication related to seat track position sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal Seat Position Sensor: Service and Repair Seat Track Position Sensor - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the front seat cushion to access the seat track position sensor (4) in a bracket (1) located on the inboard side of either the inner or outer, driver or passenger seat track (5). 3. Disconnect the seat wire harness connector (3) from the sensor connector receptacle located on the end of the sensor. 4. Using a small screwdriver, depress the snap feature (2) and pull the connector end of the sensor out of the bracket. 5. Remove the sensor from under the front seat. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal > Page 7742 Seat Position Sensor: Service and Repair Seat Track Position Sensor - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Reach under the front seat cushion to position the seat track position sensor (4) to the open end of the bracket (1) located on the inboard side of either the inner or outer, driver or passenger seat track (5). 2. Push the sensor firmly into the bracket until the snap feature (2) locks into place. 3. Reconnect the seat wire harness connector (3) to the sensor connector receptacle located on the end of the sensor. Be certain that the latch on the connector is fully engaged. 4. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation > Air Bag Indicator - Description Malfunction Lamp / Indicator: Description and Operation Air Bag Indicator - Description DESCRIPTION An airbag indicator is standard equipment on all instrument clusters. However, the instrument cluster can be programmed to disable this indicator on vehicles that are not equipped with the airbag system, which is not available in some markets. This indicator is located in the center of the speedometer, in the area above and left of the speedometer needle hub. The airbag indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Airbag in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The airbag indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation > Air Bag Indicator - Description > Page 7747 Malfunction Lamp / Indicator: Description and Operation Air Bag Indicator - Operation OPERATION The airbag indicator gives an indication to the vehicle operator when the airbag system, or a circuit or component of the system is ineffective. The airbag indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Occupant Restraint Controller (ORC) over the Controller Area Network (CAN) data bus. The airbag indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the airbag indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the on position the airbag indicator illuminates for about six to eight seconds. The entire bulb test is a function of the ORC. - Airbag Indicator Lamp-On Message - Each time the cluster receives an electronic airbag indicator lamp-on message from the ORC, the airbag indicator illuminates. The indicator remains illuminated for about twelve seconds or until the cluster receives a lamp-off message from the ORC, whichever is longer. This indicator will also be extinguished when the ignition switch is turned to the off position. Communication Error - If the cluster receives no lamp-on or lamp-off messages from the ORC for 10 consecutive message cycles, the airbag indicator illuminates. The indicator remains illuminated until the cluster receives a single lamp-off message from the ORC. - Self Test - Each time the cluster is put through the self test, the airbag indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the airbag indicator is a function of the instrument cluster. The ORC continually monitors the airbag system circuits and sensors to decide whether the system is in good operating condition. The ORC then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the ORC sends a lamp-on message after the bulb test, it indicates that the ORC has detected a system malfunction or that the airbags and seatbelt tensioners may not deploy when required, or may deploy when not required. The ORC stores a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the airbag indicator fails to illuminate due to an open or short in the cluster airbag indicator circuit, the cluster sends a message notifying the ORC of the condition, the instrument cluster and the ORC each store a DTC, and the cluster flashes the seatbelt indicator on and off as a backup to notify the vehicle operator. Use a diagnostic scan tool for proper diagnosis of the airbag system, the ORC, the CCN, the CAN data bus or the electronic communication related to airbag indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations Air Bag Control Module: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Locations > Page 7752 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 32 Way Air Bag Control Module: Diagrams Occupant Restraint Controller Module C1 (Body) 32 Way Connector C1 - (BODY) 32 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (BODY) 32 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 32 Way > Page 7755 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Diagrams > Occupant Restraint Controller Module C1 (Body) 32 Way > Page 7756 Air Bag Control Module: Diagrams Occupant Restraint Controller Module C2 (Side AIRBAG) 24 Way Connector C2 - (SIDE AIRBAG) 24 WAY MODULE-OCCUPANT RESTRAINT CONTROLLER - (SIDE AIRBAG) 24 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description Air Bag Control Module: Description and Operation Occupant Restraint Controller - Description DESCRIPTION The Occupant Restraint Controller (ORC) (1) is secured with three screws to a stamped steel mounting bracket welded onto the top of the floor panel transmission tunnel just behind the front seat crossmember and beneath the center floor console in the passenger compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum ORC housing is the electronic circuitry of the ORC which includes a microprocessor, an electronic impact sensor, an electronic safing sensor, and an energy storage capacitor. A stamped metal cover plate is secured to the bottom of the ORC housing with four screws to enclose and protect the internal electronic circuitry and components. An arrow (3) printed on the label (2) on the top of the ORC housing provides a visual verification of the proper orientation of the unit, and should always be pointed toward the front of the vehicle. The ORC housing has integral mounting flanges on three corners. The mounting flange to the right of the connector receptacle has an integral locating pin on its lower surface. Both right side flanges have round mounting holes, while the flange on the left side has a slotted mounting hole. A molded plastic electrical connector (4) with 2 receptacles, one containing 24 terminal pins and the other containing 32 terminal pins, exits the forward facing side of the ORC housing. These terminal pins connect the ORC to the vehicle electrical system through two dedicated take outs and connectors of the body wire harness. The impact sensor and safing sensor internal to the ORC are calibrated for the specific vehicle, and are only serviced as a unit with the ORC. In addition, there are unique versions of the ORC for vehicles with or without the optional side curtain airbags. The ORC cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Description and Operation > Occupant Restraint Controller - Description > Page 7759 Air Bag Control Module: Description and Operation Occupant Restraint Controller - Operation OPERATION The microprocessor in the Occupant Restraint Controller (ORC) contains the Supplemental Restraint System (SRS) logic circuits and controls all of the SRS components. The ORC uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is used for control of the airbag indicator in the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and for SRS diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. See: Air Bag Systems/Malfunction Lamp / Indicator/Description and Operation/Air Bag Indicator - Operation. The ORC microprocessor continuously monitors all of the SRS electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets an active and stored Diagnostic Trouble Code (DTC) and sends electronic messages to the EMIC over the CAN data bus to turn ON the airbag indicator. An active fault only remains for the duration of the fault, or in some cases for the duration of the current ignition switch cycle, while a stored fault causes a DTC to be stored in memory by the ORC. For some DTCs, if a fault does not recur for a number of ignition cycles, the ORC will automatically erase the stored DTC. For other internal faults, the stored DTC is latched forever. The ORC receives battery current through two circuits; a fused ignition switch output (run) circuit through a fuse in the Junction Block (JB), and a fused ignition switch output (run-start) circuit through a second fuse in the JB. The ORC receives ground through a ground circuit and take out of the instrument panel wire harness. This take out has a single eyelet terminal connector that is secured by a ground screw near the center of the instrument panel structural support. These connections allow the ORC to be operational whenever the ignition switch is in the START or ON positions. The ORC also contains an energy-storage capacitor. When the ignition switch is in the START or ON positions, this capacitor is continually being charged with enough electrical energy to deploy the SRS components for up to one second following a battery disconnect or failure. The purpose of the capacitor is to provide backup SRS protection in case there is a loss of battery current supply to the ORC during an impact. Two sensors are contained within the ORC, an electronic impact sensor and a safing sensor. The ORC also monitors inputs from two remote front impact sensors located on the back of the right and left vertical members of the radiator support near the front of the vehicle. The electronic impact sensors are accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. The ORC also monitors inputs from an internal rollover sensor and six additional remote impact sensors located on the left and right inner B-pillars and quarter inner panels to control deployment of the side curtain airbag units. The safing sensor is an electronic accelerometer sensor within the ORC that provides an additional logic input to the ORC microprocessor. The safing sensor is used to verify the need for a SRS component deployment by detecting impact energy of a lesser magnitude than that of the primary electronic impact sensors, and must exceed a safing threshold in order for the airbags to deploy. A second safing sensor within the ORC provides confirmation to the ORC microprocessor of side impact forces. This second safing sensor is a bi-directional unit that detects impact forces from either side of the vehicle. Pre-programmed decision algorithms in the ORC microprocessor determine when the deceleration rate as signaled by the impact sensors and the safing sensors indicate an impact that is severe enough to require SRS protection and, based upon the severity of the monitored impact, determines the level of front airbag deployment force required for each front seating position. When the programmed conditions are met, the ORC sends the proper electrical signals to deploy the dual multistage front airbags at the programmed force levels, the front seat belt tensioners and either side curtain airbag unit. The hard wired inputs and outputs for the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the ORC or the electronic controls or communication between other modules and devices that provide features of the SRS. The most reliable, efficient, and accurate means to diagnose the ORC or the electronic controls and communication related to ORC operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal Air Bag Control Module: Service and Repair Occupant Restraint Controller - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side SRS components in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side SRS components will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the Supplemental Restraint System (SRS) components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. Remove the center console from the top of the floor panel transmission tunnel. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Removal. 3. Disconnect the two body wire harness connectors (1) from the Occupant Restraint Controller (ORC) (2) connector receptacles located on the forward facing side of the module. To disconnect the wire harness connectors from the ORC, depress the release tab and lift the lever arm on each connector. 4. Remove the three screws (3) that secure the ORC to the ORC bracket (4) that is welded onto the top of the floor panel transmission tunnel. 5. Remove the ORC from the floor panel transmission tunnel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Occupant Restraint Controller - Removal > Page 7762 Air Bag Control Module: Service and Repair Occupant Restraint Controller - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with side curtain airbags, disable the Supplemental Restraint System (SRS) before attempting any Occupant Restraint Controller (ORC) diagnosis or service. The ORC contains a rollover sensor, which enables the system to deploy the side SRS components in the event of a vehicle rollover event. If an ORC is accidentally rolled during service while still connected to battery power, the side SRS components will deploy. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the Occupant Restraint Controller (ORC), as it can damage the impact sensor or affect its calibration. The ORC contains the impact sensor, which enables the system to deploy the Supplemental Restraint System (SRS) components. If an ORC is accidentally dropped during service, the module must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper SRS component deployment. 1. Carefully position the Occupant Restraint Controller (ORC) (2) to the ORC bracket (4) on the floor panel transmission tunnel. When the ORC is correctly positioned, the arrow on the ORC label will be pointed forward in the vehicle and the locating pin on the bottom of the right ORC mounting flange will be engaged into the locating hole in the ORC bracket. 2. Install and tighten the three screws (3) that secure the ORC to the ORC bracket that is welded onto the floor panel transmission tunnel. Tighten the screws to 11 Nm (8 ft. lbs.). CAUTION: The lever arms of the wire harness connectors for the ORC MUST be in the unlatched position before they are inserted into their connector receptacles on the ORC or they may become damaged. 3. Reconnect the two body wire harness connectors (1) to the ORC connector receptacles located on the forward facing side of the module. Be certain that the latches on both connectors are each fully engaged. 4. Reinstall the center console onto the top of the floor panel transmission tunnel. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Floor Console - Installation. 5. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Child Seat Anchor - Description Child Seat Tether Attachment: Description and Operation Child Seat Anchor - Description DESCRIPTION This vehicle is equipped with a Lower Anchors and Tether for CHildren, or LATCH child restraint anchorage system. The LATCH system provides for the installation of suitable child restraints in certain seating positions without using the standard equipment seat belt provided for that seating position. The second row seats in this vehicle are equipped with a fixed-position child restraint upper tether anchor (2) for both outboard seating positions as well as the center position of vehicles so equipped, and child restraint lower anchors (1) for the two outboard seating positions only. On vehicles equipped with a split bench third row seat there is also an upper tether anchor provided for the center seating position of that seat, but no lower anchors. The upper tether anchors (3) are integral to the second row seat cushion frames. One anchor is integral to the cushion frame of the center seat section (2), and one is integral to cushion frames of each outboard seat section (1). These anchors are each constructed from a heavy-gauge steel wire loop that is securely welded to the seat cushion frame. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Child Seat Anchor - Description > Page 7769 The upper tether anchor (3) for the third row split bench seat is integral to the left seat back panel (1). This anchor is also constructed of a heavy gauge steel wire loop that is welded to the seat back panel and surrounded by a molded plastic bezel (3). The child restraint upper tether anchors cannot be adjusted or repaired and, if ineffective or damaged, they must be replaced as a unit with their respective second row seat cushion frame unit or third row seat back panel. The lower anchors (2) for this vehicle are also integral to their respective second row outboard seat cushion frame. These anchors are also constructed from a heavy-gauge steel wire loop that is securely welded to the seat cushion frame. They are each accessed from the front of their respective seats, at each side where the seat back (1) meets the seat cushion (3). These lower anchors cannot be adjusted or repaired and, if ineffective or damaged, they must be replaced as a unit with the second row seat cushion frame unit. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Description and Operation > Child Seat Anchor - Description > Page 7770 Child Seat Tether Attachment: Description and Operation Child Seat Anchor - Operation OPERATION All vehicles manufactured for sale in the United States and Canada are required to be equipped with a Lower Anchors and Tether for CHildren, or LATCH child restraint anchorage system. The second row seats in this vehicle have two pairs of anchor provisions for installing a LATCH-compatible child seat. A single seat may be mounted in the second row center seating position of vehicles so equipped, or one in each outboard seating position. With LATCH, child seats are secured by direct attachment to the vehicle seat structure, rather than by the seat belts. With LATCH-compatible child seats, lower anchors attach to the seat structure through heavy-gauge wire loops located at the intersection between the seat cushion and the seat back surfaces. Upper tether anchors are integral to the second row seat cushion frames and the third row split bench seat back panel to secure the top tether strap of child seats equipped with this feature. These upper tether anchors work with both LATCH-compatible and other child seats equipped with a top tether strap. The owner's information packet in the vehicle glove box contains details and suggestions on the proper use of all of the factory-installed child restraint anchors. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal Seat Belt Buckle: Service and Repair Seat Belt Buckle - Removal Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. Remove the front seat and seat track from the floor panel as a unit. See: Body and Frame/Seats/Service and Repair/Seat, Front/Seat - Removal. 3. Remove the screws that secure the seat cushion side shield to the inboard side of the seat cushion frame (3) and remove the shield. 4. Remove the nut (2) that secures the front seat belt buckle anchor to the stud near the back of the inboard seat cushion frame. 5. Remove the buckle from the seat. Second Row - Center SECOND ROW - CENTER WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7775 1. Fold and tumble the right outboard second row seat for easiest access to the center seat back right hinge bracket cover (1). 2. Remove the three screws (3) that secure the cover to the center seat back right hinge bracket (2) and remove the cover. 3. Remove the screw (3) that secures the second row center seat belt buckle anchor (1) to the hinge bracket (2) and remove the buckle. Second Row - Outboard SECOND ROW - OUTBOARD WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7776 1. Fold and tumble the outboard second row seat for easiest access to the latch bracket cover (1) on the inboard side of the seat. 2. Remove the two screws (3) that secure the cover to the seat latch bracket (2) and remove the cover. 3. Remove the nut (2) that secures the second row outboard seat belt buckle anchor (1) to the latch bracket (3) and remove the buckle. Third Row Bench Seat THIRD ROW BENCH SEAT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7777 1. Move the third row seat cushion to its storage position, but leave the third row seat back in its upright position for easiest access to the seat belt buckle and bracket unit (1) on the rear floor panel. 2. Remove the screw (3) that secures the bracket to the floor and remove the bracket and buckles from the floor panel as a unit. Third Row Split Bench Seat THIRD ROW SPLIT BENCH SEAT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: Before you begin the removal procedures, with the third row seat backs folded down, look closely between the rear edge of the seat back panel and the front edge of the rear floor storage bin cover to determine whether the two blind rivets securing either the left anchor bracket (4) (for the left outboard and center anchor buckles) or the right anchor bracket (6) (for the right outboard and center buckles) have been previously removed. These blind rivets are used as an assembly aid during the manufacturing process and, once removed, they do not require reinstallation. BLIND RIVETS PRESENT 1. If the blind rivets are present, remove the third row split bench seat (3) from the rear floor panel (5) and the vehicle. See: Body and Frame/Seats/Service and Repair/Seat, Front/Seat - Removal. 2. Using an appropriate drill or chisel, remove the two blind rivets that secure the buckle anchor bracket (4 or 6) to the back of the seat cushion frame. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7778 3. Remove the buckles and anchor bracket from the seat cushion frame as a unit. BLIND RIVETS ABSENT 1. If the blind rivets are absent, remove the two pivot screws that secure the front of the left seat cushion frame to the brackets on the rear floor panel (5). 2. Fold the left seat cushion up against the left seat back (3) for access to the two buckle anchor brackets (4 or 6). 3. Remove the plastic plug (2) from the buckle anchor bracket to be removed. 4. Remove the screw (1) that secures the buckle anchor bracket to the rear floor panel. 5. Remove the buckles and anchor bracket from the seat cushion frame as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7779 Seat Belt Buckle: Service and Repair Seat Belt Buckle - Installation Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the supplemental restraint system before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the supplemental restraint system. Failure to take the proper precautions could result in accidental airbag deployment. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the front seat belt buckle lower anchor (1) onto the stud near the rear of the inboard seat cushion frame (3). Be certain the anti-rotation tab on the anchor is engaged in the clearance hole of the frame. 2. Install and tighten the nut (2) that secures the anchor to the frame. Tighten the nut to 43 Nm (32 ft. lbs.). 3. Position the seat cushion side shield to the inboard seat cushion frame. 4. Install and tighten the screws that secure the shield to the frame. Tighten the screws to 1 Nm (9 in. lbs.). 5. Reinstall the front seat and seat track to the floor panel as a unit. See: Body and Frame/Seats/Service and Repair/Seat, Front/Seat - Installation. 6. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The supplemental restraint system verification test procedure should be performed following service of any supplemental restraint system component. See: Service and Repair. Second Row - Center SECOND ROW - CENTER WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7780 possible serious or fatal injury. 1. Position the second row center seat belt buckle anchor (1) to the right seat back hinge bracket (2). Be certain the anti-rotation tab on the anchor is engaged in the clearance hole of the bracket. 2. Install and tighten the screw (3) that secures the anchor to the bracket. Tighten the screw to 43 Nm (32 ft. lbs.). 3. Position the center seat back right hinge bracket cover (1) onto the bracket (2). 4. Install and tighten the three screws (3) that secure the cover to the bracket. Tighten the screws to 2 Nm (20 in. lbs.). 5. Unfold and restore the right outboard second row seat to its upright position. Second Row - Outboard SECOND ROW - OUTBOARD WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7781 1. Position the second row outboard seat belt buckle anchor (1) to the seat latch bracket (3). Be certain the anti-rotation tab on the anchor is engaged in the clearance notch of the bracket. 2. Install and tighten the nut (2) that secures the anchor to the bracket. Tighten the nut to 43 Nm (32 ft. lbs.). 3. Position the outboard seat latch bracket cover (1) onto the bracket (2). 4. Install and tighten the two screws (3) that secure the cover to the bracket. Tighten the screws to 2 Nm (20 in. lbs.). 5. Unfold and restore the outboard second row seat to its upright position. Third Row Bench THIRD ROW BENCH WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7782 1. Position the third row seat belt buckle and anchor bracket unit (1) to the rear floor panel. Be certain the anti-rotation tab on the anchor bracket is engaged in the clearance hole (2) in the floor. 2. Install and tighten the screw (3) that secures the anchor bracket to the floor. Tighten the screw to 43 Nm (32 ft. lbs.). 3. Restore the third row seat cushion to its seating position. Third Row Split Bench Seat THIRD ROW SPLIT BENCH SEAT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The blind rivets that secure the buckle anchor brackets (4 and 6) to the seat cushion frame are used as an assembly aid during the manufacturing process and, once removed, they do not require reinstallation. 1. If the third row seat (3) was removed from the vehicle for blind rivet removal, reinstall the seat to the rear floor panel (5), but do not reinstall the two front pivot screws for the left seat cushion.See: Body and Frame/Seats/Service and Repair/Seat, Front/Seat - Installation. 2. The left seat cushion must be folded up against the left seat back for access to the two buckle anchor bracket (4 or 6) locations at the back of the seat cushion frame. 3. Position the buckle anchor bracket (4 or 6) to the back of the seat cushion frame. 4. Install and tighten the screw (1) that secures the buckle anchor bracket to the rear floor panel. Tighten the screw to 49 Nm (36 ft. lbs.). 5. Reinstall the plastic plug (2) onto the buckle anchor bracket. 6. Fold the left seat cushion down. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle - Removal > Page 7783 7. Install and tighten the two pivot screws that secure the front of the left seat cushion frame to the brackets on the rear floor panel. Tighten the screws to 35 Nm (26 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 7787 Seat Belt Buckle Switch: Diagrams Connector - (LEFT SEAT) 2 WAY SWITCH-SEAT BELT-DRIVER - (LEFT SEAT) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Driver Seat Belt Switch - Description Seat Belt Buckle Switch: Description and Operation Driver Seat Belt Switch - Description DESCRIPTION The seat belt switch (4) is a small, normally open, single pole, single throw, plunger (3) actuated, momentary switch. One seat belt switch is installed on the seat belt retractor frame (2) over the retractor spool (1) for the driver side front seat. The seat belt switch includes an integral connector that is connected to the vehicle electrical system through a take out and connector of the body wire harness. The seat belt switch cannot be adjusted or repaired and, if ineffective or damaged, the entire front seat belt and retractor unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Driver Seat Belt Switch - Description > Page 7790 Seat Belt Buckle Switch: Description and Operation Driver Seat Belt Switch - Operation OPERATION The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch sense circuit to ground. Conversely, when the seat belt tip-half webbing is wound onto the retractor spool the switch plunger is depressed, opening the ground path. The EMIC monitors the seat belt switch status, then controls the illumination of the seatbelt indicator and the generation of audible electronic chime tones based upon that input. The seat belt switch receives ground through its connection to the body wire harness from another take out of the body wire harness. An eyelet terminal connector on that ground take out is secured under a ground screw. The seat belt switch is connected in series between ground and the seat belt switch sense input of the EMIC. The seat belt switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Seat Belt Turning Loop Adjuster - Removal Seat Belt Height Adjuster: Service and Repair Front Seat Belt Turning Loop Adjuster - Removal FRONT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Unsnap the upper edge of the trim cover (3) from the front seat belt turning loop (1) and disengage the tab (2) on the lower edge of the cover to access the turning loop screw. 2. Remove the screw (4) that secures the seat belt turning loop (5) to the height adjuster (2) on the upper B-pillar. 3. Remove the seat belt turning loop from the height adjuster. 4. Remove the upper trim (1) from the inside of the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Seat Belt Turning Loop Adjuster - Removal > Page 7795 5. Remove the two screws (1) that secure the height adjuster (3) to the B-pillar (2). 6. Remove the adjuster from the B-pillar. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Seat Belt Turning Loop Adjuster - Removal > Page 7796 Seat Belt Height Adjuster: Service and Repair Seat Belt Turning Loop Adjuster - Removal SECOND ROW - OUTBOARD WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Unsnap the upper edge of the trim cover (3) from the second row outboard seat belt turning loop (1) and disengage the tab (2) on the lower edge of the cover to access the turning loop screw. 2. Remove the screw (3) that secures the seat belt turning loop (4) to the height adjuster (1) on the upper C-pillar (5). 3. Remove the seat belt turning loop from the height adjuster. 4. Remove the upper trim (2) from the inside of the C-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Seat Belt Turning Loop Adjuster - Removal > Page 7797 5. Remove the two screws (2) that secure the height adjuster (3) to the C-pillar (1). 6. Remove the adjuster from the C-pillar. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Seat Belt Turning Loop Adjuster - Removal > Page 7798 Seat Belt Height Adjuster: Service and Repair Front Seat Belt Turning Loop Adjuster - Installation FRONT WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the seat belt turning loop adjuster (3) to the B-pillar (2). 2. Install and tighten the two screws (1) that secure the adjuster to the B-pillar. Tighten the screws to 39 Nm (29 ft. lbs.). 3. Reinstall the upper trim (1) onto the inside of the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. 4. Position the seat belt turning loop (5) onto the height adjuster (2) on the upper B-pillar. 5. Install and tighten the screw (4) that secures the turning loop to the height adjuster. Tighten the screw to 39 Nm (29 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Seat Belt Turning Loop Adjuster - Removal > Page 7799 6. Engage the tab (2) on the lower edge of the trim cover (3) in the slot below the screw in the turning loop (1). Then press the upper edge of the trim cover over the top of the turning loop until it snaps into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Seat Belt Turning Loop Adjuster - Removal > Page 7800 Seat Belt Height Adjuster: Service and Repair Seat Belt Turning Loop Adjuster - Installation SECOND ROW - OUTBOARD WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the seat belt turning loop adjuster (3) to the C-pillar (1). 2. Install and tighten the two screws (2) that secure the adjuster to the C-pillar. Tighten the screws to 39 Nm (29 ft. lbs.). 3. Reinstall the upper trim (2) onto the inside of the C-pillar (5). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Installation. 4. Position the seat belt turning loop (4) to the height adjuster (1) on the upper C-pillar. 5. Install and tighten the screw (3) that secures the turning loop to the height adjuster. Tighten the screw to 39 Nm (29 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Front Seat Belt Turning Loop Adjuster - Removal > Page 7801 6. Engage the tab (2) on the lower edge of the trim cover (3) in the slot below the screw in the turning loop (1). Then press the upper edge of the trim cover over the top of the turning loop until it snaps into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation > Seat Belt Warning Lamp - Description Seat Belt Reminder Lamp: Description and Operation Seat Belt Warning Lamp - Description DESCRIPTION A seatbelt indicator is standard equipment on all instrument clusters. This indicator is located near the upper edge of the instrument cluster, between the minor gauge set and the speedometer. The seatbelt indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Seat Belt in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The seatbelt indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation > Seat Belt Warning Lamp - Description > Page 7806 Seat Belt Reminder Lamp: Description and Operation Seat Belt Warning Lamp - Operation OPERATION The seatbelt indicator gives an indication to the vehicle operator of the status of the driver side front seatbelt. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hardwired input from the seatbelt switch in the driver side front seatbelt retractor through the seat belt indicator driver circuit. The seatbelt indicator also includes a programmable enhanced seatbelt reminder or beltminder feature that is enabled when the vehicle is shipped from the factory. This beltminder feature can be disabled and enabled by the customer using a specific programming event sequence, or by the dealer using a diagnostic scan tool. The seatbelt indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the seatbelt indicator for the following reasons: Seatbelt Reminder Function - Each time the cluster receives a battery current input on the fused ignition switch output (run-start) circuit, the indicator illuminates as a seatbelt reminder for about six seconds, or until the ignition switch turns to the OFF position, whichever occurs first. This reminder function occurs regardless of the status of the seatbelt switch input to the cluster. - Driver Side Front Seatbelt Not Buckled - Beltminder Active - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the START or ON positions, the indicator illuminates. In addition, if the driver side front seatbelt remains unbuckled about 60 seconds after the conclusion of the seatbelt reminder function with the vehicle speed greater than about 8 kilometers-per-hour (5 miles-per-hour), the seatbelt indicator begins to cycle between flashing on and off for 3 seconds, then lighting solid for 2 seconds. The seatbelt indicator continues to cycle between flashing and solid illumination for 13 complete cycles, until the seatbelt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch turns to the OFF position, whichever occurs first. - Driver Side Front Seatbelt Not Buckled - Beltminder Inactive - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seatbelt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the START or ON positions, the indicator illuminates. The seatbelt indicator remains illuminated until the seatbelt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch turns to the OFF position, whichever occurs first. - Airbag Indicator Backup - If the instrument cluster detects a fault in the airbag indicator circuit it sends an electronic message indicating the fault to the Occupant Restraint Controller (ORC), then flash the seatbelt indicator on and off. The cluster continues to flash the indicator until the airbag indicator circuit fault is resolved, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the seatbelt indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The seatbelt switch is connected in series between ground and the seatbelt indicator driver input to the instrument cluster, also known as the Cab Compartment Node (CCN). Use conventional diagnostic tools and procedures to diagnose the hardwired seatbelt switch input to the instrument cluster. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation > Page 7807 Seat Belt Reminder Lamp: Testing and Inspection ENHANCED SEATBELT REMINDER PROGRAMMING The seatbelt indicator also includes a programmable enhanced seatbelt reminder or BELTMINDER feature that is enabled when the vehicle is shipped from the factory. This BELTMINDER feature provides extended and modified visual seatbelt indicator and audible chime warning responses to an unbuckled driver side front seat belt. The BELTMINDER feature may be disabled or enabled by the customer using the programming sequence that follows, or by the dealer using a diagnostic scan tool. CUSTOMER PROGRAMMING SEQUENCE NOTE: The following sequence of events must occur within 60 seconds of the ignition switch being placed in the ON position in order for the programming to be completed successfully. 1. With all doors closed and the ignition switch in any position except ON or START, buckle the driver side front seat belt. 2. Turn the ignition switch to the ON position and wait for the seatbelt indicator reminder function to conclude (about six seconds). 3. Unbuckle and buckle the driver side front seat belt three or more times, ending with the belt buckled. 4. Turn the ignition switch to any position except ON or START to toggle the BELTMINDER feature from its current setting (from active to inactive, or from inactive to active). A single chime tone will provide an audible confirmation that the programming sequence has been successfully completed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Seat Belt Retractor - Description Seat Belt Retractor: Description and Operation Seat Belt Retractor - Description DESCRIPTION The seat belt retractors used in all seating positions include an inertia-type, emergency locking mechanism as standard equipment. However, the retractor locking mechanism for the second row center seating position is mechanically switchable from an emergency locking retractor to an automatic locking retractor. The primary function of this feature is to securely accommodate a child seat in the second row center seating position of the vehicle without the need for a self-cinching seat belt tip half latch plate unit or another supplemental device that would be required to prevent the seat belt webbing from unwinding freely from the retractor spool of an inertia-type emergency locking retractor mechanism. The automatic locking mechanism is integral to the second row center seat belt and retractor unit and is concealed beneath a molded plastic cover located on the side of the retractor spool. The retractor is secured to the center section seat back frame and is concealed beneath the seat back trim. The automatic locking mechanism cannot be adjusted or repaired and, if ineffective or damaged, the entire second row center seat belt and retractor unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Seat Belt Retractor - Description > Page 7812 Seat Belt Retractor: Description and Operation Seat Belt Retractor - Operation OPERATION The locked mode of the retractor is engaged and the automatic locking retractor is switched from operating as a standard inertia-type emergency locking retractor by first buckling the combination lap and shoulder belt buckle. Then grasp the shoulder belt and pull all of the webbing out of the retractor. Once all of the belt webbing is extracted from the spool, the retractor will automatically become engaged in the pre-locked automatic locking mode and will make an audible clicking or ratcheting sound as the shoulder belt is allowed to retract to confirm that the automatic locking mode is now engaged. Once the automatic locking mode is engaged, the retractor will remain locked and the belt will remain tight around whatever it is restraining. The retractor is returned to standard emergency locking (inertia) mode by unbuckling the combination lap and shoulder belt buckle and allowing the belt webbing to be almost fully retracted onto the retractor spool. The emergency locking mode is confirmed by the absence of the audible clicking or ratcheting sound as the belt webbing retracts. This mode will allow the belt to unwind from and wind onto the retractor spool freely unless and until a predetermined inertia load is sensed, or until the retractor is again switched to the automatic locking mode. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal Seat Belt Retractor: Service and Repair Seat Belt Retractor - Removal Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. See: Service and Repair . 1. Adjust the front seat to its most forward position for easiest access to the front seat belt lower anchor and the B-pillar trim. 2. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 3. Using a trim stick or another suitable wide flat-bladed tool, gently pry the seat belt anchor cover (2) to remove it from the rear of the outboard seat side shield (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7815 4. Remove the screw (2) that secures the lower anchor (3) to the bracket on the outboard side of the front seat cushion frame. 5. Unsnap the upper edge of the trim cover (3) from the front seat belt turning loop (1) and disengage the tab (2) on the lower edge of the cover to access the turning loop screw. 6. Remove the screw (4) that secures the seat belt turning loop (5) to the height adjuster (2) on the upper B-pillar. 7. Remove the seat belt turning loop from the height adjuster. 8. Remove the upper trim (1) from the inside of the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7816 9. Remove the lower trim (2) from the inside of the B-pillar (4). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. 10. Remove the screw (3) that secures the belt web guide (1) to the B-pillar. 11. Disconnect the body wire harness connector (5) from the seat belt tensioner initiator on the retractor (7). 12. Disconnect the second body wire harness connector from the seat belt switch connector receptacle on the retractor. 13. Remove the screw (8) that secures the upper retractor bracket to the B-pillar. 14. Remove the screw (6) that secures the lower retractor bracket to the B-pillar. 15. Disengage the engagement tab on the upper retractor bracket from the engagement slot in the B-pillar. 16. Remove the front seat belt and retractor from the B-pillar as a unit. Third Row Center THIRD ROW CENTER WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the upper liftgate opening trim from the inside of the rear header (1) in the upper liftgate opening. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Description and Operation/Rear Header Panel - Description. 2. Route the seat belt (2) and lower anchor latch plates through the clearance hole in the upper liftgate opening trim panel. 3. Pull the top of the left upper D-pillar trim away from the D-pillar far enough to access the retractor mounting provisions. 4. Remove the screw (4) that secures the retractor bracket to the inside of the rear header near the left D-pillar (3). 5. Remove the third row center seat belt and retractor from the rear header as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7817 Third Row Outboard THIRD ROW OUTBOARD WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Move the third row seat cushion to its storage position, but leave the third row seat back in its upright position for easiest access to the seat belt lower anchor (2) on the quarter inner panel (3). 2. Remove the screw (1) that secures the lower anchor to the tapping plate on the quarter inner panel. 3. Remove the D-pillar trim panel (1) from the inside of the upper D-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Removal. 4. Route the seat belt (2) and lower anchor through the access hole in the D-pillar trim panel. 5. Remove the screw (4) that secures the seat belt turning loop (3) to the inside of the upper D-pillar. 6. Remove the turning loop from the D-pillar. 7. Remove the quarter trim panel from the lower D-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 8. Remove the screw (6) that secures the retractor bracket (5) to the lower D-pillar. 9. Remove the third row seat belt and retractor from the D-pillar as a unit. Second Row - Center Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7818 SECOND ROW - CENTER WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Fold and tumble the left outboard second row seat for easiest access to the center seat back left hinge bracket cover (1). 2. Remove the three screws (2) that secure the cover to the center seat back left hinge bracket (3) and remove the cover. 3. Remove the screw (2) that secures the second row center seat belt lower anchor (1) to the hinge bracket (3) and remove the anchor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7819 4. Remove the two screws (3) that secure the belt web guide bezel (2) to the top of the center seat back panel and remove the bezel from the seat back and the belt. 5. Remove the trim cover (1) from the center seat back. See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Back Cover - Removal. 6. Remove the three screws (3) that secure the retractor (2) to the seat back frame (1). 7. Lift the retractor upward far enough to disengage the two tabs (4) on the retractor bracket from the keyed slots in the seat back frame. 8. Remove the second row seat belt and retractor from between the seat back foam and frame as a unit. Second Row - Outboard SECOND ROW - OUTBOARD WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7820 1. Unsnap the upper edge of the trim cover (3) from the second row outboard seat belt turning loop (1) and disengage the tab (2) on the lower edge of the cover to access the turning loop screw. 2. Remove the screw (3) that secures the seat belt turning loop (4) to the height adjuster (1) on the upper C-pillar (5). 3. Remove the seat belt turning loop from the height adjuster. 4. Remove the upper trim (2) from the inside of the C-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Removal. 5. Remove the screw (4) that secures the lower seat belt anchor (3) to the rear floor panel. 6. Remove the quarter trim panel (2) from the lower C-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7821 7. Route the seat belt lower anchor and turning loop through the access hole in the quarter trim panel. 8. Remove the screw (5) that secures the retractor bracket (1) to the lower C-pillar. 9. Lift the retractor upward far enough to disengage the retractor tab from the engagement hole in the C-pillar. 10. Remove the second row outboard seat belt and retractor from the C-pillar as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7822 Seat Belt Retractor: Service and Repair Seat Belt Retractor - Installation Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: The following procedure is for replacement of an ineffective or damaged seat belt and retractor unit. The front retractor also includes a seat belt tensioner. If the front seat belt or retractor is ineffective or damaged, but the seat belt tensioner is not deployed, review the recommended procedures for handling non-deployed supplemental restraints. See: Service and Repair . If the seat belt tensioner has been deployed, review the recommended procedures for service after a supplemental restraint deployment before removing the unit from the vehicle. See: Service and Repair . 1. Position the front seat belt and retractor (7) to the B-pillar (4) as a unit. Be certain to engage the engagement tab on the upper retractor bracket into the engagement slot in the lower B-pillar. 2. Loosely install the screw (6) that secures the lower retractor bracket to the B-pillar. 3. Install and tighten the screw (8) that secures the upper retractor bracket to the B-pillar. Tighten the screw to 4 Nm (35 in. lbs.). 4. Tighten the screw (6) that secures the lower retractor bracket to the B-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 5. Reconnect the body wire harness connector (5) to the seat belt tensioner initiator on the retractor. 6. Reconnect the second body wire harness connector to the seat belt switch connector receptacle on the retractor. 7. Position the belt web guide (1) to the B-pillar. 8. Install and tighten the screw (3) that secures the belt web guide to the B-pillar. Tighten the screw to 4 Nm (35 in. lbs.). 9. Reinstall the lower trim onto the inside of the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7823 10. Reinstall the upper trim (1) onto the inside of the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. 11. Position the seat belt turning loop (5) onto the height adjuster (2) on the upper B-pillar. 12. Install and tighten the screw (4) that secures the turning loop to the height adjuster. Tighten the screw to 39 Nm (29 ft. lbs.). 13. Engage the tab (2) on the lower edge of the trim cover (3) in the slot below the screw in the turning loop (1). Then press the upper edge of the trim cover over the top of the turning loop until it snaps into place. 14. Position the front seat belt lower anchor (3) to the bracket on the outboard side of the front seat cushion frame. 15. Install and tighten the screw (2) that secures the lower anchor to the bracket on the outboard side of the front seat cushion frame. Tighten the screw to 39 Nm (29 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7824 16. Align the seat belt anchor cover (2) to the opening near the rear of the outboard seat side shield (3). Using hand pressure, press firmly and evenly on the cover until it snaps into place. 17. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Third Row Center THIRD ROW CENTER WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the third row center seat belt and retractor (2) to the rear header (1) near the left D-pillar (3) as a unit. 2. Install and tighten the screw (4) that secures the retractor bracket to the inside of the rear header. Tighten the screw to 40 Nm (29 ft. lbs.). 3. Restore the top of the left upper D-pillar trim to its mountings on the D-pillar. 4. Route the seat belt and lower anchor latch plates through the clearance hole in the upper liftgate opening trim panel. 5. Reinstall the upper liftgate opening trim onto the inside of the rear header in the upper liftgate opening. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Description and Operation/Rear Header Panel - Description. Third Row Outboard THIRD ROW OUTBOARD Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7825 WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Check to be certain that the molded plastic retractor cup (2) is properly installed in the retractor mounting hole (1) of the inner D-pillar, and that it is in good condition. 2. Position the third row outboard seat belt and retractor (5) to the D-pillar as a unit. 3. Install and tighten the screw (6) that secures the retractor bracket to the lower D-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 4. Position the seat belt turning loop (3) to the inside of the upper D-pillar. 5. Install and tighten the screw (4) that secures the turning loop to the D-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 6. Reinstall the quarter trim panel to the lower D-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 7. Route the seat belt (2) and lower anchor through the access hole in the D-pillar trim panel (1). 8. Reinstall the D-pillar trim panel to the inside of the upper D-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7826 9. Position the seat belt lower anchor (2) to the tapping plate (3) on the quarter inner panel. 10. Install and tighten the screw (1) that secures the lower anchor to the tapping plate. Tighten the screw to 39 Nm (29 ft. lbs.). 11. Restore the third row seat cushion to its seating position. Second Row - Center SECOND ROW - CENTER WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the second row seat belt and retractor (2) between the seat back foam pad and frame (1) as a unit. 2. Engage the two tabs (4) on the retractor bracket into the keyed slots in the seat back frame. 3. Install and tighten the three screws (3) that secure the retractor to the seat back frame. Tighten the screws to 27 Nm (20 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7827 4. Reinstall the trim cover (1) onto the center seat back. See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Back Cover - Installation. 5. Install the seat belt lower anchor through the belt web guide bezel (2) and position the bezel onto the top of the center seat back panel. 6. Install and tighten the two screws (3) that secure the bezel to the top of the seat back. Tighten the screws to 2 Nm (20 in. lbs.). 7. Position the second row center seat belt lower anchor (1) to the hinge bracket (3). Be certain the anti-rotation tab on the anchor is engaged in the clearance hole of the bracket. 8. Install and tighten the screw (2) that secures the lower anchor to the bracket. Tighten the screw to 43 Nm (32 ft. lbs.). 9. Position the center seat back left hinge bracket cover (1) onto the bracket (3). 10. Install and tighten the three screws (2) that secure the cover to the bracket. Tighten the screws to 2 Nm (20 in. lbs.). 11. Unfold and restore the left outboard second row seat to its upright position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7828 Second Row - Outboard SECOND ROW - OUTBOARD WARNING: To avoid serious or fatal injury during and following any seat belt or child restraint anchor service, carefully inspect all seat belts, buckles, mounting hardware, retractors, tether straps, and anchors for proper installation, operation, or damage. Replace any belt that is cut, frayed, or torn. Straighten any belt that is twisted. Tighten any loose fasteners. Replace any belt that has a damaged or ineffective buckle or retractor. Replace any belt that has a bent or damaged latch plate or anchor plate. Replace any child restraint anchor or the unit to which the anchor is integral that has been bent or damaged. Never attempt to repair a seat belt or child restraint component. Always replace damaged or ineffective seat belt and child restraint components with the correct, new and unused replacement parts listed in the Chrysler Mopar (R) Parts Catalog. Failure to follow these instructions may result in possible serious or fatal injury. 1. Check to be certain that the molded plastic retractor cup is properly installed in the retractor mounting hole of the inner C-pillar, and that it is in good condition. 2. Position the second row outboard seat belt and retractor (1) to the C-pillar as a unit. 3. Engage the tab on the retractor bracket into the engagement hole in the C-pillar. 4. Install and tighten the screw (5) that secures the retractor to the lower C-pillar. Tighten the screw to 39 Nm (29 ft. lbs.). 5. Route the seat belt lower anchor and turning loop through the access hole in the quarter trim panel. 6. Reinstall the quarter trim panel onto the lower C-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 7. Position the lower seat belt anchor (3) to the rear floor panel. 8. Install and tighten the screw (4) that secures the lower seat belt anchor to the floor. Tighten the screw to 39 Nm (29 ft. lbs.). 9. Reinstall the upper trim (2) onto the inside of the C-pillar (5). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Installation. 10. Position the seat belt turning loop (4) to the height adjuster (1) on the upper C-pillar. 11. Install and tighten the screw (3) that secures the turning loop to the height adjuster. Tighten the screw to 39 Nm (29 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor - Removal > Page 7829 12. Engage the tab (2) on the lower edge of the trim cover (3) in the slot below the screw in the turning loop (1). Then press the upper edge of the trim cover over the top of the turning loop until it snaps into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Driver Seat Belt Tensioner Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Locations > Driver Seat Belt Tensioner > Page 7834 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Seat Belt Tensioner (Body) 2 Way Seat Belt Tensioner: Diagrams Driver Seat Belt Tensioner (Body) 2 Way Connector - (BODY) 2 WAY SEAT BELT-TENSIONER-DRIVER - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Diagrams > Driver Seat Belt Tensioner (Body) 2 Way > Page 7837 Seat Belt Tensioner: Diagrams Passenger Seat Belt Tensioner (Body) 2 Way Connector - (BODY) 2 WAY SEAT BELT-TENSIONER-PASSENGER - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Seat Belt Tensioner - Description Seat Belt Tensioner: Description and Operation Seat Belt Tensioner - Description DESCRIPTION Seat belt tensioners supplement the dual front airbags for this vehicle. The seat belt tensioners are integral to the front seat belt retractor units, which are secured to the inner B-pillar on the right and left sides of the vehicle. The retractor is concealed beneath the molded plastic inner B-pillar trim. The seat belt tensioner consists primarily of a sprocket/pinion, a steel tube, a cast metal housing, numerous steel balls, a stamped metal ball trap, a torsion bar and a small pyrotechnically activated gas generator with a connector receptacle. All of these components are located on one side of the retractor spool on the outside of the retractor housing except for the torsion bar, which serves as the spindle upon which the retractor spool rides. The seat belt tensioners are controlled by the Occupant Restraint Controller (ORC) and are connected to the vehicle electrical system through a dedicated take out of the body wire harness by a keyed and latching yellow molded plastic connector insulator to ensure a secure connection. The seat belt tensioners cannot be repaired and, if ineffective or damaged, the entire front seat belt and retractor unit must be replaced. If the front airbags have been deployed, the seat belt tensioners have also been deployed. The seat belt tensioners are not intended for reuse and must be replaced following any front airbag deployment. A growling or grinding sound while attempting to operate the seat belt retractor is a sure indication that the seat belt tensioner has been deployed and requires replacement. See: Seat Belt Retractor/Service and Repair/Seat Belt Retractor Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Tensioner > Component Information > Description and Operation > Seat Belt Tensioner - Description > Page 7840 Seat Belt Tensioner: Description and Operation Seat Belt Tensioner - Operation OPERATION The seat belt tensioners are deployed in conjunction with the dual front airbags by a signal generated by the Occupant Restraint Controller (ORC) through the driver or passenger seat belt tensioner line 1 and line 2 (or squib) circuits. When the ORC sends the proper electrical signal to the tensioners, the electrical energy generates enough heat to initiate a small pyrotechnic gas generator. The gas generator is installed in one end of a steel tube that contains numerous steel balls. As the gas expands, it pushes the steel balls through the tube into a cast metal housing, where a ball guide directs the balls into engagement with the teeth of a sprocket that is geared to one end of the retractor spool. As the balls drive past the sprocket, the sprocket turns and drives the seat belt retractor spool causing the slack to be removed from the front seat belts. The ball trap captures the balls as they leave the sprocket and are expelled from the housing. Removing excess slack from the front seat belts not only keeps the occupants properly positioned for an airbag deployment following a frontal impact of the vehicle, but also helps to reduce injuries that the occupant might experience in these situations as a result of harmful contact with the steering wheel, steering column, instrument panel or windshield. Also, the seat belt tensioner torsion bar that the retractor spool rides upon is designed to deform in order to control the loading being applied to the occupants by the seat belts during a frontal impact, further reducing the potential for occupant injuries. The ORC monitors the condition of the seat belt tensioners through circuit resistance, and will illuminate the airbag indicator in the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) and store a Diagnostic Trouble Code (DTC) for any fault that is detected. Proper diagnosis of the seat belt tensioner gas generator and the seat belt tensioner squib circuits requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Sensor/Switch > Component Information > Locations > Page 7844 Seat Sensor/Switch: Diagrams Connector - (DRIVER SEAT) 2 WAY SENSOR-SEAT TRACK POSITION-DRIVER - (DRIVER SEAT) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7850 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7851 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7852 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7853 Impact Sensor: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7854 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7855 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7856 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7857 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Left Front Impact Sensor > Page 7858 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way Impact Sensor: Diagrams Left Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 1 - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 7861 Impact Sensor: Diagrams Left Side Impact Sensor 2 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 2 - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 7862 Impact Sensor: Diagrams Right Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-RIGHT 1 - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 7863 Impact Sensor: Diagrams Left Front Impact Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-FRONT IMPACT-LEFT - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 7864 Impact Sensor: Diagrams Left Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 1 - (BODY) 4 WAY Left Side Impact Sensor 2 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-LEFT 2 - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 7865 Right Side Impact Sensor 1 (Body) 4 Way Connector - (BODY) 4 WAY SENSOR-SIDE IMPACT-RIGHT 1 - (BODY) 4 WAY Left Front Impact Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 7866 SENSOR-FRONT IMPACT-LEFT - (HEADLAMP AND DASH) 2 WAY Right Front Impact Sensor (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-FRONT IMPACT-RIGHT - (HEADLAMP AND DASH) 2 WAY Right Side Impact Sensor 2 (Body) 4 Way Connector - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Diagrams > Left Side Impact Sensor 1 (Body) 4 Way > Page 7867 SENSOR-SIDE IMPACT-RIGHT 2 - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description Impact Sensor: Description and Operation Impact Sensor - Description Front FRONT Two front impact sensors (1) are used on this vehicle, one each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each front sensor is secured with a screw to the backs of the right and left vertical members of the radiator support within the engine compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left front impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The front impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Side SIDE Four side impact sensors (1) are used on this vehicle to support the standard side curtain airbags, two each for the left and right sides of the vehicle. These sensors are mounted remotely from the impact sensor that is internal to the Occupant Restraint Controller (ORC). Each side sensor is secured with a screw to the right or left B-pillar and quarter inner panel within the passenger compartment. The sensor housing has an integral connector receptacle (4), an integral anti-rotation pin (3), and an integral mounting hole (2) with a metal sleeve to provide crush protection. The right and left side impact sensors are identical in construction and calibration. A cavity in the center of the molded black plastic impact sensor housing contains the electronic circuitry of the sensor which includes an electronic communication chip and an electronic impact sensor. Potting material fills the cavity to seal and protect the internal electronic circuitry and components. The side impact sensors are each connected to the vehicle electrical system through a dedicated take out and connector of the body wire harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 7870 The impact sensors cannot be repaired or adjusted and, if damaged or ineffective, they must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation > Impact Sensor - Description > Page 7871 Impact Sensor: Description and Operation Impact Sensor - Operation Front FRONT The front impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through dedicated left and right sensor plus and minus circuits from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the front impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to front impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Side SIDE The side impact sensors are electronic accelerometers that sense the rate of vehicle deceleration, which provides verification of the direction and severity of an impact. Each sensor also contains an electronic communication chip that allows the unit to communicate the sensor status as well as sensor fault information to the microprocessor in the Occupant Restraint Controller (ORC). The ORC microprocessor continuously monitors all of the side passive restraint system electrical circuits to determine the system readiness. If the ORC detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and controls the airbag indicator operation accordingly. The impact sensors each receive battery current and ground through the same left or right sensor plus and minus circuits in a series arrangement from the ORC. The impact sensors and the ORC communicate by modulating the voltage in the sensor plus circuit. The hard wired circuits between the side impact sensors and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the impact sensors or the electronic controls or communication between other modules and devices that provide features of the supplemental restraint system. The most reliable, efficient, and accurate means to diagnose the impact sensors or the electronic controls and communication related to side impact sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal Impact Sensor: Service and Repair Impact Sensor - Removal Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. Remove the screw (3) that secures the right or left front impact sensor (1) to the back of the right or left radiator support vertical member (2). 3. Disconnect the headlamp and dash wire harness connector (4) from the sensor connector receptacle. 4. Remove the right or left front impact sensor from the engine compartment. Side - B-Pillar SIDE - B-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7874 1. Adjust the driver or passenger side front seat to its most forward position for easiest access to the B-pillar trim. 2. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 3. Remove the lower trim from the inside of the right or left B-pillar (1). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. 4. Remove the screw (4) that secures the side impact sensor (3) to the lower B-pillar. 5. Disconnect the body wire harness connector (2) from the sensor connector receptacle. 6. Remove the sensor from the B-pillar. Side - C/D-Pillar SIDE - C/D-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7875 two minutes for the system capacitors to discharge before further service. 2. Remove the quarter trim panel from the quarter inner panel near the lower C-pillar (5). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Remove the screw (1) that secures the side impact sensor (2) to the quarter inner panel. 4. Disconnect the body wire harness (4) connector from the sensor connector receptacle. 5. Remove the sensor from the quarter inner panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7876 Impact Sensor: Service and Repair Impact Sensor - Installation Front FRONT WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the front impact sensor, as it can damage the impact sensor or affect its calibration. The front impact sensor enables the system to deploy the front Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper front SRS component deployment. 1. Position the right or left front impact sensor (1) into the engine compartment. 2. Reconnect the headlamp and dash wire harness connector (4) to the sensor connector receptacle. 3. Position the sensor onto the back of the right or left radiator support vertical member (2). Be certain that the anti-rotation pin on the back of the sensor is engaged in the lower clearance hole of the radiator support. 4. Install and tighten the screw (3) that secures the sensor to the back of the support vertical member. Tighten the screw to 6 Nm (55 in. lbs.). 5. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Side - B-Pillar SIDE - B-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7877 1. Check to be certain that the rivet nut used to secure the side impact sensor (3) is properly installed in the inner B-pillar (1),and that it is in good condition. 2. Position the side impact sensor near the inner B-pillar. 3. Reconnect the body wire harness connector (2) to the sensor connector receptacle. 4. Position the sensor onto the inner B-pillar. Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole (5) of the B-pillar. 5. Install and tighten the screw (4) that secures the sensor to the inner B-pillar. Tighten the screw to 6 Nm (50 in. lbs.). 6. Reinstall the lower trim onto the inside of the B-pillar. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. 7. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Side - C/D-Pillar SIDE - C/D-PILLAR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: To avoid serious or fatal injury, never strike or drop the side impact sensor, as it can damage the impact sensor or affect its calibration. The side impact sensor enables the system to deploy the side Supplemental Restraint System (SRS) components. If an impact sensor is accidentally dropped during service, the sensor must be scrapped and replaced with a new unit. Failure to observe this warning could result in accidental, incomplete, or improper side SRS component deployment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Impact Sensor - Removal > Page 7878 1. Check to be certain that the rivet nut (3) used to secure the side impact sensor (2) is properly installed in the quarter inner panel, and that it is in good condition. 2. Position the side impact sensor near the quarter inner panel. 3. Reconnect the body wire harness (4) connector to the sensor connector receptacle. 4. Position the sensor onto the quarter inner panel. Be certain that the anti-rotation pin on the back of the sensor is engaged in the clearance hole of the quarter inner panel. 5. Install and tighten the screw (1) that secures the sensor to the quarter inner panel. Tighten the screw to 6 Nm (50 in. lbs.). 6. Reinstall the quarter trim panel onto the quarter inner panel near the lower C-pillar (5). See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 7. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 7882 Seat Belt Buckle Switch: Diagrams Connector - (LEFT SEAT) 2 WAY SWITCH-SEAT BELT-DRIVER - (LEFT SEAT) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Driver Seat Belt Switch - Description Seat Belt Buckle Switch: Description and Operation Driver Seat Belt Switch - Description DESCRIPTION The seat belt switch (4) is a small, normally open, single pole, single throw, plunger (3) actuated, momentary switch. One seat belt switch is installed on the seat belt retractor frame (2) over the retractor spool (1) for the driver side front seat. The seat belt switch includes an integral connector that is connected to the vehicle electrical system through a take out and connector of the body wire harness. The seat belt switch cannot be adjusted or repaired and, if ineffective or damaged, the entire front seat belt and retractor unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Description and Operation > Driver Seat Belt Switch - Description > Page 7885 Seat Belt Buckle Switch: Description and Operation Driver Seat Belt Switch - Operation OPERATION The seat belt switch is designed to control a path to ground for the seat belt switch sense input of the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The seat belt switch plunger is actuated by the seat belt webbing wound onto the seat belt retractor spool. When the seat belt tip-half webbing is pulled out of the retractor far enough to engage the seat belt buckle-half, the switch plunger is extended and closes the seat belt switch sense circuit to ground. Conversely, when the seat belt tip-half webbing is wound onto the retractor spool the switch plunger is depressed, opening the ground path. The EMIC monitors the seat belt switch status, then controls the illumination of the seatbelt indicator and the generation of audible electronic chime tones based upon that input. The seat belt switch receives ground through its connection to the body wire harness from another take out of the body wire harness. An eyelet terminal connector on that ground take out is secured under a ground screw. The seat belt switch is connected in series between ground and the seat belt switch sense input of the EMIC. The seat belt switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description Seat Position Sensor: Description and Operation Seat Track Position Sensor - Description DESCRIPTION The seat track position sensor (1) is a Hall Effect-type sensor. This sensor consists of a Hall Effect Integrated Circuit (IC) chip encased in potting material within a cavity of the molded plastic sensor housing. The sensor housing has two integral snap features (3) and snaps into a stamped metal bracket located on the inboard side of one of the seat adjuster tracks on the front seat of vehicles so equipped. A molded connector receptacle (2) integral to the sensor housing is connected to the vehicle electrical system through a connector and take out of the seat wire harness beneath the front seat cushion frame. The seat track position sensor cannot be adjusted or repaired and, if ineffective or damaged, the entire sensor must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Description and Operation > Seat Track Position Sensor - Description > Page 7890 Seat Position Sensor: Description and Operation Seat Track Position Sensor - Operation OPERATION The seat track position sensor is designed to provide a seat position data input to the Occupant Restraint Controller (ORC) indicating whether the driver side front seat is in a full forward or a not full forward position. The ORC uses this data as an additional logic input for use in determining the appropriate deployment force to be used when deploying the multistage driver side front airbag. The seat track position sensor receives a nominal five volt supply from the ORC. The sensor communicates the seat position by modulating the voltage returned to the ORC on a sensor data circuit. The ORC also monitors the condition of the sensor circuits and will store a Diagnostic Trouble Code (DTC) for any fault that is detected. The ORC then sends messages over the Controller Area Network (CAN) data bus to control the illumination of the airbag indicator in the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The hard wired circuits between the seat track position sensor and the ORC may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the seat track position sensor or the electronic controls and communication between other modules and devices that provide features of the Supplemental Restraint System (SRS). The most reliable, efficient, and accurate means to diagnose the seat track position sensor or the electronic controls and communication related to seat track position sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal Seat Position Sensor: Service and Repair Seat Track Position Sensor - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitor to discharge before further service. 2. Reach under the front seat cushion to access the seat track position sensor (4) in a bracket (1) located on the inboard side of either the inner or outer, driver or passenger seat track (5). 3. Disconnect the seat wire harness connector (3) from the sensor connector receptacle located on the end of the sensor. 4. Using a small screwdriver, depress the snap feature (2) and pull the connector end of the sensor out of the bracket. 5. Remove the sensor from under the front seat. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Position Sensor > Component Information > Service and Repair > Seat Track Position Sensor - Removal > Page 7893 Seat Position Sensor: Service and Repair Seat Track Position Sensor - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Reach under the front seat cushion to position the seat track position sensor (4) to the open end of the bracket (1) located on the inboard side of either the inner or outer, driver or passenger seat track (5). 2. Push the sensor firmly into the bracket until the snap feature (2) locks into place. 3. Reconnect the seat wire harness connector (3) to the sensor connector receptacle located on the end of the sensor. Be certain that the latch on the connector is fully engaged. 4. Do not reconnect the battery negative cable at this time. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, the service disconnect must also remain disconnected from the high voltage battery pack. The Supplemental Restraint System (SRS) verification test procedure should be performed following service of any SRS component. See: Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Sensor/Switch > Component Information > Locations > Page 7897 Seat Sensor/Switch: Diagrams Connector - (DRIVER SEAT) 2 WAY SENSOR-SEAT TRACK POSITION-DRIVER - (DRIVER SEAT) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Accessory Delay Relay is located in the Junction Block (JB). Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 7903 Accessory Delay Relay: Diagrams Connector (IN JB) RELAY-ACCESSORY DELAY (IN JB) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair > Navigation Radio Antenna - Removal Antenna, Navigation: Service and Repair Navigation Radio Antenna - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Remove the radio See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Removal. 3. Remove the instrument panel defroster grille See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille - Removal. 4. Remove the passenger airbag See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Passenger Air Bag Removal. 5. Remove the antenna mounting fasteners. 6. Remove the navigation radio antenna. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Service and Repair > Navigation Radio Antenna - Removal > Page 7909 Antenna, Navigation: Service and Repair Navigation Radio Antenna - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Position antenna to instrument panel. 2. Connect antenna to radio. 3. Install radio See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio Installation. 4. Install and tighten mounting fasteners. 5. Install instrument panel defroster grille See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille - Installation. 6. Install passenger airbag See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Passenger Air Bag Installation. 7. Connect battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, TV > Component Information > Service and Repair > Satellite Video Antenna Mast - Removal Antenna, TV: Service and Repair Satellite Video Antenna Mast - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Lower the front headliner. See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Removal. 3. Disconnect the electrical connectors. 4. Remove the mounting fastener and remove the antenna. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, TV > Component Information > Service and Repair > Satellite Video Antenna Mast - Removal > Page 7914 Antenna, TV: Service and Repair Satellite Video Antenna Mast - Installation INSTALLATION 1. Install the antenna and mounting fastener. 2. Connect the electrical connectors. 3. Install the headliner. See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner Installation. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Keyless Start Antenna > Component Information > Description and Operation Keyless Start Antenna: Description and Operation DESCRIPTION The Remote Start Antenna Module Assembly consists of an electrical connection to the WCM/SKREEM (1), a length of coax cable (2), two mounting clips (3) and (4), and a control module/antenna (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal Keyless Start Antenna: Service and Repair Remote Start Antenna - Removal REMOVAL The Remote Start Antenna Module Assembly consists of an electrical connection to the WCM/SKREEM (1), a length of coax cable (2), two mounting clips (3) and (4), and a control module/antenna (5). The control module (3) is located under the instrument panel cover (2). The module electrical connector plugs into the WCM/SKREEM at the right side of the steering column. 1. Disconnect and isolate negative battery cable. 2. Remove steering column trim panel (knee blocker). 3. Remove steering column shrouds. 4. Remove left instrument panel (IP) end cap. 5. Remove IP cluster bezel. 6. Remove IP cluster and its three connectors. 7. Remove left A-pillar trim. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 7920 8. Unclip upper IP bezel (defroster). 9. Remove two module mounting screws (4) from module (3). 10. Disconnect coax cable retainers (3) and (4) from IP. 11. Remove two WCM/SKREEM mounting screws at steering column (1). 12. Remove WCM/SKREEM from steering column (1). 13. Disconnect coax cable electrical connector (2) at WCM/SKREEM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 7921 14. Remove module (2) from top of instrument panel while fishing coax cable (1) through openings. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 7922 Keyless Start Antenna: Service and Repair Remote Start Antenna - Installation INSTALLATION The Remote Start Antenna Module Assembly consists of an electrical connection to the WCM/SKREEM (1), a length of coax cable (2), two mounting clips (3) and (4), and a control module/antenna (5). 1. Fish coax cable (1) through openings on top of instrument panel. Position module (2) to top of instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 7923 2. Install two module mounting screws (4) to module (3). 3. Connect coax cable retainers (3) and (4) to instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 7924 4. Connect coax cable electrical connector (2) to WCM/SKREEM. 5. Install WCM/SKREEM to steering column (1). 6. Clip upper instrument panel (IP) bezel (defroster). 7. Install left A-pillar trim. 8. Install IP cluster and its three connectors. 9. Install IP cluster bezel. 10. Install left IP end cap. 11. Install steering column trim panel (knee blocker). 12. Install steering column shrouds. 13. Connect negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Instrument Panel Antenna Cable - Removal Antenna Cable: Service and Repair Instrument Panel Antenna Cable - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the right side cowl trim. 3. Reach under the instrument panel outboard of the glove box to access and disconnect the antenna coaxial cable connector (1) and (2). Disconnect the connector by pulling it apart while twisting the metal connector halves. Do not pull on the cable. 4. Disengage the instrument panel antenna cable from the retainer clips on the glove box opening and instrument panel support. 5. Remove the radio See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Removal. CAUTION: Pulling the antenna cable straight out of the radio without pulling on the locking antenna connector could damage the cable or radio. 6. Disconnect the antenna cable by pulling the locking antenna connector away from the radio. 7. Pull the antenna cable out through the radio opening in the instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Instrument Panel Antenna Cable - Removal > Page 7930 Antenna Cable: Service and Repair Instrument Panel Antenna Cable - Installation INSTALLATION 1. Insert the cable through the radio opening. Route behind the glove box and attach to the retainers. 2. Connect the electrical and antenna connectors. 3. Install the radio See: Radio, Stereo, and Compact Disc/Radio/Stereo/Service and Repair/Removal and Replacement/Radio - Installation. 4. Install the cowl trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Description and Operation/Cowl Trim Panel - Description. 5. Connect the cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Sentry Key Immobilizer Module (SKREEM) - Description Alarm Module: Description and Operation Sentry Key Immobilizer Module (SKREEM) - Description DESCRIPTION The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM), and is also known as the Sentry Key Immobilizer Module (SKIM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Several unique SKREEM modules are used: one for vehicles equipped with RKE only, one for vehicles equipped with RKE and SKIS, and another version has an additional coaxial connector receptacle that allows it to receive inputs from the optional remote start antenna module. The SKREEM cannot be adjusted or repaired. If ineffective or damaged, the entire SKREEM unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Sentry Key Immobilizer Module (SKREEM) - Description > Page 7936 Alarm Module: Description and Operation Sentry Key Immobilizer Module (SKREEM) - Operation OPERATION The Sentry Key REmote Entry Module (SKREEM) (also known as the Sentry Key Immobilizer Module/SKIM or the Wireless Control Module/WCM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver and may receive RF inputs either directly through an internal antenna from the RKE key fob transmitter or, on vehicles equipped with an optional remote start system, indirectly through the external remote start antenna module. See: Body and Frame/Locks/Power Locks/Description and Operation/Power Locks Description. The SKREEM communicates over the Controller Area Network (CAN) data bus with the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Powertrain Control Module (PCM), or the diagnostic scan tool. The SKREEM and the PCM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code, called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM during SKIS initialization. In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM using the diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends an electronic valid key message to the PCM over the CAN data bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKREEM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends electronic security indicator request messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator request message from the SKREEM tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator request messages to the EMIC to turn the indicator OFF, turn the indicator ON, or to flash the indicator ON and OFF. If the security indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction or if the SKIS has become ineffective, the security indicator will stay ON solid. If the SKREEM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. See: Service and Repair. The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The hard wired circuits of the SKREEM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKREEM or the electronic controls or communication between other modules and devices that provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose the SKREEM or the electronic controls and communication related to SKREEM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal Alarm Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push gently inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 7939 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. On vehicles equipped with the optional remote start system, disconnect the coaxial cable from the coaxial connector receptacle on the SKREEM. 10. Remove the screw (2) that secures the SKREEM (1) to the steering column housing. 11. Disengage the antenna ring (3) from around the ignition lock cylinder housing (4) and remove the SKREEM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 7940 Alarm Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column with the antenna ring (3) oriented around the ignition lock cylinder housing (4). 2. Install and tighten the screw (2) that secures the SKREEM to the steering column housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). 4. On vehicles equipped with the optional remote start system, reconnect the coaxial cable to the coaxial connector receptacle on the SKREEM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 7941 5. Position the lower shroud (3) onto the steering column (4). 6. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 7. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 8. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 9. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 10. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 11. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), if the Sentry Key REmote Entry Module (SKREEM) is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. See: Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Transponder Key - Description Alarm System Transponder: Description and Operation Transponder Key - Description DESCRIPTION Each ignition key (2) used in the Sentry Key Immobilizer System (SKIS) has a transponder chip included on the circuit board (4) beneath the cover (1) of the integral Remote Keyless Entry (RKE) transmitter (3). In addition to having to be cut to match the mechanical coding of the ignition lock cylinder and programmed for operation of the RKE system, each new Sentry Key has a unique transponder identification code that is permanently programmed into it by the manufacturer, and which must be programmed into the Sentry Key REmote Entry Module (SKREEM) (also known as the Sentry Key Immobilizer Module/SKIM or the Wireless Control Module/WCM) to be recognized by the SKIS as a valid key. The Sentry Key transponder cannot be adjusted or repaired. If ineffective or damaged, the entire key and RKE transmitter unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Transponder Key - Description > Page 7946 Alarm System Transponder: Description and Operation Transponder Key - Operation OPERATION When the ignition switch is turned to the ON position, the Sentry Key REmote Entry Module (SKREEM) (also known as the Sentry Key Immobilizer Module/SKIM or the Wireless Control Module/WCM) communicates through its antenna with the Sentry Key transponder using a Radio Frequency (RF) signal. The SKREEM then listens for a RF response from the transponder through the same antenna. The Sentry Key transponder chip is within the range of the SKREEM transceiver antenna ring when it is inserted into the ignition lock cylinder. The SKREEM determines whether a valid key is present in the ignition lock cylinder based upon the response from the transponder. If a valid key is detected, that fact is communicated by the SKREEM to the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus, and the PCM allows the engine to continue running. If the PCM receives an invalid key message, or receives no message from the SKREEM over the CAN data bus, the engine will be disabled after about two seconds of operation. The Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) will also respond to the invalid key message on the CAN data bus by flashing the security indicator ON and OFF. Each Sentry Key has a unique transponder identification code permanently programmed into it by the manufacturer. Likewise, the SKREEM has a unique Secret Key code programmed into it by the manufacturer. When a Sentry Key is programmed into the memory of the SKREEM, the SKREEM stores the transponder identification code from the Sentry Key, and the Sentry Key learns the Secret Key code from the SKREEM. Once the Sentry Key learns the Secret Key code of the SKREEM, it is permanently stored in the memory of the transponder. Therefore, once a Sentry Key has been programmed to a particular vehicle, it cannot be used on any other vehicle. See: Service and Repair. The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store key-related fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a Sentry Key transponder problem is detected. The Sentry Key transponder chip can be diagnosed, and any stored DTC can be retrieved using a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System Transponder > Component Information > Description and Operation > Page 7947 Alarm System Transponder: Testing and Inspection SENTRY KEY TRANSPONDER PROGRAMMING All Sentry Keys included with the vehicle are pre-programmed to work with the Sentry Key Immobilizer System (SKIS) when it is shipped from the factory. The Sentry Key REmote Entry Module (SKREEM) (also known as the Sentry Key Immobilizer Module/SKIM or the Wireless Control Module/WCM) may be programmed to recognize up to a total of eight Sentry Keys. When programming a blank Sentry Key transponder, the key must first be cut to match the ignition switch lock cylinder in the vehicle for which it will be used. Once the additional or new key has been cut, the SKREEM must be programmed to recognize it as a valid key. There are two possible methods to program the SKREEM to recognize a new or additional valid key, the Secured Access Method and the Customer Learn Method. Following are the details of these two programming methods. SECURED ACCESS METHOD The Secured Access method applies to all vehicles. This method requires the use of a diagnostic scan tool. This method will also require that you have access to the unique four-digit PIN code that was assigned to the original SKREEM. The PIN code must be used to enter the Secured Access Mode in the SKREEM. This PIN number may be obtained from the vehicle owner, from the original vehicle invoice, or from the Chrysler Customer Center. See: Keyless Entry/Keyless Entry Module/Testing and Inspection. CUSTOMER LEARN METHOD NOTE: The Customer Learn feature is only available on domestic market vehicles, or those vehicles which have a U.S. country code designator. This programming method also requires access to at least two valid Sentry Keys. If two valid Sentry Keys are not available, or if the vehicle does not have a U.S. country code designator, the Secured Access Method MUST be used to program new or additional valid keys to the SKREEM. The Customer Learn programming method procedures are as follows: 1. Obtain the blank Sentry Key(s) that are to be programmed as valid keys for the vehicle. Cut the blank key(s) to match the ignition switch lock cylinder mechanical key codes. 2. Insert one of the two valid Sentry Keys into the ignition switch and turn the ignition switch to the ON position. 3. After the ignition switch has been in the ON position for longer than 3 seconds, but no more than 15 seconds, cycle the ignition switch back to the OFF position. Replace the first valid Sentry Key in the ignition switch lock cylinder with the second valid Sentry Key and turn the ignition switch back to the ON position. The second valid Sentry Key must be inserted in the lock cylinder within 15 seconds of removing the first valid key. 4. About 10 seconds after the completion of 3 , the security indicator in the instrument cluster will start to flash to indicate that the system has entered the Customer Learn programming mode. 5. Within 60 seconds of entering the Customer Learn programming mode, turn the ignition switch to the OFF position, replace the valid Sentry Key with a blank Sentry Key transponder, and turn the ignition switch back to the ON position. 6. About 10 seconds after the completion of 5 , the security indicator will stop flashing, stay ON solid for 3 seconds, then turn OFF to indicate that the blank Sentry Key has been successfully programmed. The SKIS will immediately exit the Customer Learn programming mode. After the ignition is cycled the vehicle may be started using the newly programmed valid Sentry Key. Each of these steps must be repeated and completed in their entirety for each additional Sentry Key that is to be programmed. If the above steps are not completed in the given sequence, or within the allotted time, the SKIS will exit the Customer Learn programming mode and the programming will be unsuccessful. The SKREEM will also automatically exit the Customer Learn programming mode if it sees a non-blank Sentry Key transponder when it should see a blank, if it has already programmed 8 valid Sentry Keys, or if the ignition switch is turned to the OFF position for more than about 50 seconds. NOTE: If an attempt is made to start the vehicle while in the Customer Learn mode (security indicator flashing), the SKIS will respond as though the vehicle were being started with an invalid key. In other words, the engine will stall after about two seconds of operation. No faults will be set. NOTE: Once a Sentry Key has been programmed as a valid key to a vehicle, it cannot be programmed as a valid key for use on any other vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Hood Ajar Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Hood Ajar Switch > Page 7952 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 7953 Hood Sensor/Switch (For Alarm): Diagrams Connector (HEV) - 2 WAY SWITCH-HOOD AJAR 2 (HEV) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in three different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic market vehicles equipped with either an optional remote starter system or the optional Hybrid Electric Vehicle (HEV) system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole. For the vehicle theft and remote start applications, the switch is secured within the stamped metal inner left fender mounting flange within the engine compartment. For the HEV applications, the switch is secured within the stamped metal inner right fender mounting flange within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system or HEV system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description > Page 7956 Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export market vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Front Control Module (FCM). The FCM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic market vehicles only - white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the FCM and the hood ajar switch sense input of the FCM. The FCM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. When the hood switch is closed (hood is open), the remote start feature is disabled. In the Hybrid Electric Vehicle (HEV) system application (white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between ground and the hood ajar switch sense input of the Powertrain Control Module (PCM). The PCM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. When the hood switch is closed (hood is open), the gasoline engine auto-start feature is disabled. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting hole, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the FCM or PCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export market vehicle theft, domestic market remote starter or the HEV systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Removal Striker STRIKER NOTE: Vehicles equipped with two hood ajar switches are also equipped with two strikers. NOTE: The hood ajar switch strikers are not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using hand pressure, slide the hood ajar switch striker (2) toward the large end of the keyed mounting hole (3) in the inner hood panel reinforcement (1) far enough to disengage it. 3. Remove the striker from the inner hood panel reinforcement and discard. Switch SWITCH NOTE: Some vehicles are equipped with two hood ajar switches. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 3. From the top of the left or right front fender inner shield, squeeze the two hood ajar switch latch tabs (1) together and pull the switch upward out of Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal > Page 7959 the mounting hole (2). 4. Pull the hood ajar switch up through the hole far enough to access and disconnect the wire harness connector (3) from the switch connector receptacle. 5. Remove the hood ajar switch from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal > Page 7960 Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Installation Striker STRIKER NOTE: Vehicles equipped with two hood ajar switches are also equipped with two strikers. NOTE: The hood ajar switch striker caps are not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) into the large end of the keyed mounting hole (3) in the inner hood panel reinforcement (1) over the hood ajar switch. 2. Using hand pressure, slide the striker upward into the small end of the mounting hole in the inner hood panel reinforcement until it is fully engaged. 3. Close and latch the hood. Switch SWITCH NOTE: Some vehicles are equipped with two hood ajar switches. 1. Position the hood ajar switch (1) near the mounting hole (2) in the left front fender inner shield. 2. Reconnect the wire harness connector (3) to the switch connector receptacle. 3. Insert the switch into the mounting hole until the integral switch latch tabs lock it into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal > Page 7961 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. 5. Close and latch the hood. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7966 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY MODULE-WIRELESS CONTROL - (INSTRUMENT PANEL) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7967 Keyless Entry Module: Testing and Inspection SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 7968 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Description and Operation Keyless Start Antenna: Description and Operation DESCRIPTION The Remote Start Antenna Module Assembly consists of an electrical connection to the WCM/SKREEM (1), a length of coax cable (2), two mounting clips (3) and (4), and a control module/antenna (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna Removal Keyless Start Antenna: Service and Repair Remote Start Antenna - Removal REMOVAL The Remote Start Antenna Module Assembly consists of an electrical connection to the WCM/SKREEM (1), a length of coax cable (2), two mounting clips (3) and (4), and a control module/antenna (5). The control module (3) is located under the instrument panel cover (2). The module electrical connector plugs into the WCM/SKREEM at the right side of the steering column. 1. Disconnect and isolate negative battery cable. 2. Remove steering column trim panel (knee blocker). 3. Remove steering column shrouds. 4. Remove left instrument panel (IP) end cap. 5. Remove IP cluster bezel. 6. Remove IP cluster and its three connectors. 7. Remove left A-pillar trim. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna Removal > Page 7975 8. Unclip upper IP bezel (defroster). 9. Remove two module mounting screws (4) from module (3). 10. Disconnect coax cable retainers (3) and (4) from IP. 11. Remove two WCM/SKREEM mounting screws at steering column (1). 12. Remove WCM/SKREEM from steering column (1). 13. Disconnect coax cable electrical connector (2) at WCM/SKREEM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna Removal > Page 7976 14. Remove module (2) from top of instrument panel while fishing coax cable (1) through openings. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna Removal > Page 7977 Keyless Start Antenna: Service and Repair Remote Start Antenna - Installation INSTALLATION The Remote Start Antenna Module Assembly consists of an electrical connection to the WCM/SKREEM (1), a length of coax cable (2), two mounting clips (3) and (4), and a control module/antenna (5). 1. Fish coax cable (1) through openings on top of instrument panel. Position module (2) to top of instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna Removal > Page 7978 2. Install two module mounting screws (4) to module (3). 3. Connect coax cable retainers (3) and (4) to instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna Removal > Page 7979 4. Connect coax cable electrical connector (2) to WCM/SKREEM. 5. Install WCM/SKREEM to steering column (1). 6. Clip upper instrument panel (IP) bezel (defroster). 7. Install left A-pillar trim. 8. Install IP cluster and its three connectors. 9. Install IP cluster bezel. 10. Install left IP end cap. 11. Install steering column trim panel (knee blocker). 12. Install steering column shrouds. 13. Connect negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair REMOTE KEYLESS ENTRY TRANSMITTER BATTERIES The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a trim stick or a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves located near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the battery with a new CR2032. Be certain that the battery is installed with the polarity correctly oriented. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together using hand pressure until they snap back into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation > Security System Indicator - Description Security Lamp/Indicator: Description and Operation Security System Indicator - Description DESCRIPTION A security indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional Vehicle Theft Security System (VTSS), this indicator is electronically disabled. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The security indicator consists of a small round cutout in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The security indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation > Security System Indicator - Description > Page 7988 Security Lamp/Indicator: Description and Operation Security System Indicator - Operation OPERATION The security indicator gives an indication to the vehicle operator when the Vehicle Theft Security System (VTSS) is arming or armed. On vehicles equipped with the Sentry Key Immobilizer System (SKIS), the security indicator also gives an indication to the vehicle operator of the status of the SKIS. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, hardwired inputs to the cluster from the various security system components and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM) (also known as the Sentry Key Immobilizer Module/SKIM or the Wireless Control Module/WCM) over the Controller Area Network (CAN) data bus. The security indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic allows the indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, the LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. Depending upon the programmed condition the indicator can be illuminated solid, flashed at a slow rate (0.5 Hertz, 12.5 percent duty cycle), or flashed at a fast rate (1 Hertz, 50 percent duty cycle). The instrument cluster turns on the security indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the security indicator illuminates for about two seconds as a bulb test. The entire bulb test is a function of the SKREEM. VTSS Indication - During the 16 second VTSS arming function, the cluster flashes the security indicator on and off repeatedly at a steady, fast rate to indicate that the VTSS is in the process of arming. Following successful VTSS arming, the cluster flashes the security indicator on and off continuously at a slower rate to indicate that the VTSS is armed. The security indicator continues flashing at the slower rate until the VTSS is disarmed or triggered. If the VTSS has alarmed and rearmed, the cluster flashes the security indicator at a steady, slow rate for about 30 seconds after the VTSS is disarmed. - SKIS Indicator Lamp-On Message - Each time the cluster receives an electronic SKIS indicator lamp-on message from the SKREEM, the security indicator will be illuminated. The indicator can be flashed on and off, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated solid or continues to flash until the cluster receives a lamp-off message from the SKREEM, or until the ignition switch is turned to the OFF position, whichever occurs first. For more information on the SKIS and the security indicator control parameters, See: Description and Operation/Vehicle Theft Security System - Operation. - Communication Error - If the cluster receives no lamp-ON or lamp-OFF messages from the SKREEM for 10 consecutive message cycles, the security indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-ON or lamp-OFF message is received from the SKREEM. - Self Test - Each time the instrument cluster is put through the self test, the security indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster circuitry controls the security indicator whenever the ignition switch is in the OFF position and the VTSS is arming, armed, or alarming. Whenever the ignition switch is in the ON or START positions, the SKREEM performs a self-test to decide whether the SKIS is in good operating condition and whether a valid key is present in the ignition lock cylinder. The SKREEM then sends the proper lamp-ON or lamp-OFF messages to the instrument cluster, also known as the Cab Compartment Node (CCN). If the cluster flashes the security indicator upon ignition on, or turns on the security indicator solid after the bulb test, it indicates that a SKIS malfunction has occurred or that the SKIS is ineffective. Using a diagnostic scan tool for proper diagnosis of the VTSS, the SKIS, the SKREEM, the CCN, the CAN data bus or the electronic communication related to security indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Navigation/Telecommunication - Description Cellular Phone: Description and Operation Navigation/Telecommunication - Description DESCRIPTION TELECOMMUNICATIONS NOTE: On vehicles equipped with the navigation radio, the hands free module is located within the radio. The hands-free cellular system uses Bluetooth(TM) technology to provide wireless communication between the operator's compatible cellular telephone and the vehicle's on-board receiver. The system uses voice recognition technology to control operation. The incoming voice is broadcast through the vehicle's radio speakers, automatically overriding any other audio signals on the front speakers when the hands-free system is in use. A microphone in the rear view mirror picks up vehicle occupant's voices. If a call is in progress when the ignition is switched off, the hands-free system will continue to operate for up to 45 seconds as part of the Accessory Relay Delay function. Thereafter, the call can continue on the hand-held telephone. The center console front storage compartment includes a cellular telephone holder, but the system will communicate with a telephone that is anywhere within the vehicle. However, covering the hand held phone or the hands-free phone module with a metal object may block the signal. The system will recognize up to seven telephones, each of which is given a spoken identification by the user during the setup process. The system includes Spanish and French voice recognition in addition to English. Two buttons on the rearview mirror, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or voice command) button prompts the hands-free system to listen for a voice command. NAVIGATION The navigation system offers several new customer features for expanded usability and convenience with hands-free voice-activated operation in addition to the touch screen buttons. The navigation system uses the Bluetooth microphone in the rear view mirror. Navigation routes can be based on a variety of formats including some of the following: - Destination entry by street intersection, city, zip code, street name, street address and number, state/province/country and phone number - Stop/change route - Save current position - Personal menu, including Guide Me Home (Go Home), Trip Itinerary, List of Saved Locations, Favorite Points of Interest (from a data base), Manage Personal User and Choose User - Personal Interests including recent routes, address book, Where Am I Now, Emergency (police stations, Dodge dealerships, fire stations, hospitals and emergency care centers), Trail and geocoordinates - Route options include shortest, quickest, maximize freeways, minimize freeways, avoid toll roads and avoid ferries - Navigation can be put into DEMO mode to enhance trip planning This navigation system will support Traffic Messaging. Traffic Messaging displays voice and pop up warning messages for medium and high priority situations on the route such as road closures due to accidents/hazardous situations and it can even generate a traffic detour for a traffic event located on the route. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Description and Operation > Navigation/Telecommunication - Description > Page 7993 Cellular Phone: Description and Operation Navigation/Telecommunication - Operation OPERATION TELECOMMUNICATION Two buttons on the radio, identified with ISO icons, control the system: A "phone" button turns the system on and off; a "voice recognition" (or voice command) button prompts the hands-free system to listen for a voice command. The system includes the following features: - Phonebook - Stores telephone numbers for later recall by name or other verbal identification, called a voice tag, and memory location. - Four memory locations - Home, Work, Cellular and Pager. A maximum of 32 unique names or voice tags may be stored at the same time, with a different number in each of the four memory locations. - Voice tag dialing - Dials the number associated with a voice tag and memory location. - Digit dialing - Dials the telephone number by recognizing the names of the digits as they are spoken. - Receiving calls - A voice prompt notifies the user of an incoming call. A voice response accepts or rejects the call without manual intervention. - Privacy Mode - Switches the call to the handheld telephone and the hands-free system and back again using the "voice recognition" (or "voice command") button and a voice command, if desired. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Hands Free Module (HFM) - Removal Cellular Phone: Service and Repair Hands Free Module (HFM) - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the instrument panel end cap (3). 3. Remove the glove box. 4. Remove the door scuff plate. 5. Remove the cowl trim panel. 6. Remove the mounting fasteners. 7. Disconnect the electrical harness connector and remove the module (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Service and Repair > Hands Free Module (HFM) - Removal > Page 7996 Cellular Phone: Service and Repair Hands Free Module (HFM) - Installation INSTALLATION 1. Connect electrical harness connector and position module. 2. Install mounting fasteners. 3. Install the cowl trim panel. 4. Install the door scuff plate. 5. Install the glove box. 6. Install instrument panel end cap. 7. Connect battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams > Park Assist Module C1 (Parktronics) 12 Way Parking Assist Control Module: Diagrams Park Assist Module C1 (Parktronics) 12 Way Connector C1 (PARKTRONICS) - 12 WAY MODULE-PARK ASSIST (PARKTRONICS) - 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Diagrams > Park Assist Module C1 (Parktronics) 12 Way > Page 8003 Parking Assist Control Module: Diagrams Park Assist Module C2 (Parktronics) 8 Way Connector C2 (PARKTRONICS) - 8 WAY MODULE-PARK ASSIST (PARKTRONICS) - 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Description and Operation > Park Assist Module - Description Parking Assist Control Module: Description and Operation Park Assist Module - Description DESCRIPTION The Park Assist Module (3) is secured with three push-in plastic fasteners through three mounting tabs (2) integral to the module housing to the left inner quarter panel above the left rear wheel housing. The module is concealed beneath the quarter inner trim panel. Concealed within the molded plastic park assist module housing is a microprocessor and the other electronic circuitry of the module. The module housing is sealed to enclose and protect the internal electronic circuitry. The module software is flash programmable. Two connector receptacles (1) containing terminal pins are integral to the rearward-facing side of the housing. The module is connected to the vehicle electrical system through two dedicated take outs and connectors of the body wire harness. The park assist module cannot be adjusted or repaired and, if damaged or ineffective, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Description and Operation > Park Assist Module - Description > Page 8006 Parking Assist Control Module: Description and Operation Park Assist Module - Operation OPERATION The microprocessor in the park assist module contains the park assist system logic circuits. The module uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is also used for park assist system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The module provides voltage to the four park assist sensors located behind the rear bumper fascia and to the park assist display located in the headliner just forward of the liftgate opening header. The module then monitors return inputs from each of the sensors and the display on dedicated hard wired data communication circuits. The sensor inputs allow the module to determine when an obstacle is in the rear path of the vehicle and enables the module to calculate the relative location of the obstacle, and whether the distance to that obstacle is increasing or decreasing. Pre-programmed decision algorithms and calibrations allow the module microprocessor to determine the appropriate park assist system outputs based upon the inputs received from the park assist sensors and electronic messages received from other modules in the vehicle over the CAN data bus. When the programmed conditions are met the module sends electronic messages to the park assist displays over a dedicated serial bus to obtain the proper park assist system visual and audible outputs. The module also broadcasts electronic messages over the CAN data bus to enable the other electronic features of the park assist system. The park assist module microprocessor continuously monitors all of the park assist system electrical circuits and components to determine the system readiness. If the module detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and sends the appropriate electronic messages to the instrument cluster over the CAN data bus to control operation of certain park assist system audible warnings and textual messages displayed in the Electronic Vehicle Information Center (EVIC). The park assist module receives battery current on a fused ignition switch output (run-start) circuit through a fuse in the Junction Block (JB). The module receives ground through a ground circuit and take out of the body wire harness. These connections allow the module to be operational whenever the ignition switch is in the START or ON positions. The hard wired circuits between components related to the park assist module may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the park assist module or the electronic controls or communication between modules and other devices that provide some features of the park assist system. The most reliable, efficient, and accurate means to diagnose the park assist module or the electronic controls and communication related to park assist module operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Service and Repair > Park Assist Module - Removal Parking Assist Control Module: Service and Repair Park Assist Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the trim from the left quarter inner panel to access the park assist module (5), which is located behind the power liftgate module (3) to the rear of the C-pillar (2) and above the left rear wheel housing. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel Removal. 3. Disconnect the two body wire harness connectors (1) from the park assist module connector receptacles. 4. Remove the three plastic push-in fasteners (4) that secure the module to the left quarter inner panel. 5. Remove the module from the left quarter inner panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Control Module > Component Information > Service and Repair > Park Assist Module - Removal > Page 8009 Parking Assist Control Module: Service and Repair Park Assist Module - Installation INSTALLATION 1. Position the park assist module (5) to the left quarter inner panel, behind the power liftgate module (3) to the rear of the C-pillar (2) and above the left rear wheel housing. 2. Secure the module to the left quarter inner panel using three plastic push-in fasteners (4). 3. Reconnect the two body wire harness connectors (1) to the module connector receptacles. 4. Reinstall the trim onto the left quarter inner panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 5. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Park Assist Sensor 8 (Park Assist) (Fascia RPA Harness) 3 Way Parking Assist Distance Sensor: Diagrams Park Assist Sensor 8 (Park Assist) (Fascia RPA Harness) 3 Way Connector (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY SENSOR-PARK ASSIST 8 (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Park Assist Sensor 8 (Park Assist) (Fascia RPA Harness) 3 Way > Page 8015 Parking Assist Distance Sensor: Diagrams Park Assist Sensor 9 (Park Assist) (Fascia RPA Harness) 3 Way Connector (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY SENSOR-PARK ASSIST 9 (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Park Assist Sensor 8 (Park Assist) (Fascia RPA Harness) 3 Way > Page 8016 Parking Assist Distance Sensor: Diagrams Park Assist Sensor 10 (Park Assist) (Fascia RPA Harness) 3 Way Connector (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY SENSOR-PARK ASSIST 10 (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Diagrams > Park Assist Sensor 8 (Park Assist) (Fascia RPA Harness) 3 Way > Page 8017 Parking Assist Distance Sensor: Diagrams Park Assist Sensor 11 (Park Assist) (Fascia RPA Harness) 3 Way Connector (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY SENSOR-PARK ASSIST 11 (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Description and Operation > Park Assist Sensor - Description Parking Assist Distance Sensor: Description and Operation Park Assist Sensor - Description DESCRIPTION Vehicles equipped with the park assist system have four park assist sensors (1) installed on the rear bumper fascia. Only the membrane (3) of each sensor is visible through a hole in the outer vertical surface of the fascia. The remainder of each sensor including the sensor mounting bracket, the sensor spacer and the sensor wiring connection is concealed behind the fascia. A sensor wire harness behind the fascia connects the sensors to the vehicle electrical system. Each of the four sensors is identical in construction and is interchangeable. The electronic circuitry and a communication chip for each sensor is enclosed and protected within the molded black plastic sensor housing. The housing includes an integral connector receptacle (4) and two integral latch tabs (2). The sensor membrane extends from the surface of the sensor housing, and is finished to match or contrast with the outer surface of the fascia. The numbering system for the park assist sensors allows for up to twelve sensors on the vehicle, six front and six rear. The sensors are numbered in a clockwise manner starting at the left front bumper. The left front sensor (if equipped with front park assist) is the number 1 sensor. The numbering continues in a clockwise direction around the vehicle. Since this vehicle uses only four rear sensors, sensor numbers 7 and 12 are omitted, so the left rear sensor is the number 11 sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Description and Operation > Park Assist Sensor - Description > Page 8020 A resilient O-ring spacer around the circumference of each of the four sensor membranes (2) isolates the membrane from the openings in the fascia (1). Each sensor is snapped into its own dedicated molded plastic mounting bracket. Each mounting bracket is heat-staked to the back side of the rear fascia. The park assist sensors cannot be adjusted or repaired. If ineffective or damaged they must be replaced. The sensors and the spacers are each available for individual service replacement. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Description and Operation > Park Assist Sensor - Description > Page 8021 Parking Assist Distance Sensor: Description and Operation Park Assist Sensor - Operation OPERATION The park assist sensors are ultrasonic transceivers that are completely controlled by the park assist module. The sensors transmit and receive ultrasonic signals. The sensors each receive battery current and ground in parallel from the module, but are each connected to individual dedicated serial bus communication circuits to the module. Each sensor membrane is oscillated, then quieted by the module in a pulsing fashion. While the sensor membrane oscillates, it emits an ultrasonic signal. This signal will bounce or echo off of objects in the path of the vehicle. While quieted, each membrane receives the echoes of the ultrasonic signals it and the other sensors have transmitted. The sensors then communicate this echo data over the serial bus lines back to the module. The microprocessor in the module uses the intervals between the ultrasonic transmission and reception data from the sensors to calculate the distance to any obstacles identified by the ultrasonic echoes. The hard wired circuits between components related to the park assist sensors may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the park assist sensors or the electronic controls or communication between modules and other devices that provide some features of the park assist system. The most reliable, efficient, and accurate means to diagnose the park assist sensors or the electronic controls and communication related to park assist sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Park Assist Sensor - Removal Parking Assist Distance Sensor: Service and Repair Park Assist Sensor - Removal REMOVAL NOTE: The park assist sensors (3) and the sensor spacers (O-rings) are each available for separate service replacement. The sensor brackets (5) are bonded to and integral to the back side of the rear bumper fascia (2). 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. NOTE: The two outboard rear park assist sensors can be accessed for service with the rear bumper fascia installed on the vehicle. 2. For the two inboard rear park assist sensors only, remove the bumper fascia from the rear of the vehicle. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Removal. 3. From the back of the fascia (2), disconnect the wire harness connector (4) from the park assist sensor (3) connector receptacle. 4. Carefully pry the sensor bracket (5) latch features (1) away from the top and bottom latch tabs of the sensor far enough to disengage the sensor from the bracket. 5. Disengage the O-ring spacer from around the circumference of the sensor membrane protrusion. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Distance Sensor > Component Information > Service and Repair > Park Assist Sensor - Removal > Page 8024 Parking Assist Distance Sensor: Service and Repair Park Assist Sensor - Installation INSTALLATION NOTE: The park assist sensors (3) and the sensor spacers (O-rings) are each available for separate service replacement. The sensor brackets (5) are bonded to and integral to the back side of the rear bumper fascia (2). 1. Engage the O-ring spacer around the circumference of the sensor membrane protrusion. NOTE: Production and all service replacement O-ring spacers are tapered. The wide side (base) of the O-ring should be seated against the sensor housing and the narrow side should be oriented toward the outer surface of the sensor membrane and the rear fascia. 2. Align and insert the sensor (3) into the sensor bracket (5) on the back of the rear bumper fascia (2) until the bracket latch features (1) are fully engaged over the top and bottom latch tabs of the sensor. Be certain that the sensor membrane is flush with the outer surface of the fascia. NOTE: Be certain that each sensor membrane is properly centered in the openings of the rear fascia and that the O-ring spacers are not pinched. Improper centering or pinched O-rings can be detrimental to proper park assist sensor operation. 3. From the back of the fascia, reconnect the wire harness connector (4) to the sensor connector receptacle. 4. For the two inboard rear park assist sensors only, reinstall the bumper fascia onto the rear of the vehicle. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Installation. 5. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Description and Operation > Chime/Buzzer - Description Parking Assist Warning Indicator: Description and Operation Chime/Buzzer - Description PARK ASSIST SYSTEM A park assist system is an optional factory-installed electronic parking aid. During parking and other similar vehicle maneuvers this system alerts the vehicle operator to obstacles located in the path immediately behind the vehicle which, due to the surrounding rear vehicle structure, might be otherwise difficult to perceive. When an object is detected, the system uses an electromechanical transducer and Light Emitting Diode (LED) indicators within the park assist display unit to provide the vehicle operator with visual and audible indications of the presence and proximity of such objects. The park assist system includes the following major components, which are described in further detail elsewhere in this service information: - Electronic Vehicle Information Center (1) - In vehicles equipped with the optional park assist system, the Electronic Vehicle Information Center (EVIC) in the overhead console displays textual warnings and error messages and emits audible warnings related to the current operating status of the park assist system and provides an interface that allows the vehicle operator to manually disable or enable the system using the customer programmable features option. - Park Assist Display (3) - Vehicles equipped with the park assist system have a park assist display unit mounted in the rear of the headliner just forward of the liftgate opening. The body of the display is concealed above the headliner where it is secured by a retainer on the back of the headliner substrate. Only the narrow, oval-shaped smoked clear lens of the display is visible on the outer surface of the headliner. - Park Assist Module (2) - Vehicles equipped with the park assist system include a park assist module which is secured through integral mounting tabs by push-in type fasteners to the quarter inner panel above the left rear wheel housing where it is concealed beneath the quarter inner trim panel. - Park Assist Sensors (4) - Vehicles equipped with the park assist system have four ultrasonic park assist sensors that are concealed behind the rear bumper fascia. Each sensor is snapped into an individual molded plastic mounting bracket located at horizontal intervals along the back side of the rear bumper fascia. Hard wired circuitry connects the various park assist system components to each other through the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other and to the vehicle electrical system through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. The park assist system components cannot be adjusted or repaired. If any of the park assist system components is damaged or ineffective, that component must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Description and Operation > Chime/Buzzer - Description > Page 8029 Parking Assist Warning Indicator: Description and Operation Chime/Buzzer - Operation PARK ASSIST SYSTEM The park assist system is active only when the ignition switch is in the ON or START positions, the parking brake is released, the transmission gear selector lever is in either the REVERSE position and the vehicle speed is less than 16 kph (10 mph) or, the DRIVE position and the vehicle speed is less than 14 kph (8 mph) on deceleration, or 18 kph (12 mph) on acceleration. In vehicles equipped with this option, the system is enabled from the factory as a default. The system can be manually disabled and enabled by the vehicle operator using the customer programmable features option of the Electronic Vehicle Information Center (EVIC) in the overhead console. Reasons for disabling the system include trailer towing and off road use. With a trailer attached to the vehicle the audible and visible park assist alerts would be incessant whenever the gear selector lever was in the REVERSE position due to the proximity of the trailer to the rear of the vehicle. Similarly, operating the vehicle off road may cause the park assist alerts to become distracting due to the proximity of large trees or boulders and the extreme rear approach angles that may be encountered while maneuvering on off road trails or terrain. When the system is disabled, a PARK ASSIST DISABLED textual message will appear in the EVIC display whenever the gear selector lever is in the REVERSE position. The microprocessor based park assist module is the central component of the park assist system. It supplies voltage to the park assist sensors and the park assist display, receives and analyzes data from the sensors, calculates and communicates the proper display information to the park assist display, performs system diagnostics, and communicates with other electronic modules in the vehicle or with a diagnostic scan tool over the Controller Area Network (CAN) data bus. The module operates on battery voltage received through a fuse in the Junction Block (JB), and is grounded through a take out and eyelet terminal of the body wire harness that is secured by a screw to the left inner D-pillar. Four ultrasonic park assist sensors in the rear bumper fascia allow the park assist system to locate and identify the proximity of nearby obstacles. These sensors each generate ultrasonic sound pulses when triggered by the park assist module, then signal the module when an echo of the reflected sound pulses is received. The detection distance range from the rear of the vehicle is about 0.3 meters (11.8 inches) to about 2.0 meters (80 inches), and the detection height range from the ground is about 0.2 meters (7.8 inches) to about 0.8 meters (31 inches). The detection area extends somewhat around both rear sides (corners) of the vehicle. The park assist display unit provides the vehicle operator with both visible and audible warnings indicating the relative range of a detected object. The display is visible to the vehicle operator over an inboard shoulder when looking rearward while backing the vehicle up, but is not visible in a properly adjusted inside rear view mirror when looking forward. The display contains two sets of eight Light Emitting Diode (LED) indicator units, one set dedicated to each side of the vehicle, and an audible chime tone transducer. The LED units are concealed beneath a smoked oval lens and are not clearly visible when they are not illuminated. When the park assist system is active and no obstacles are detected (stand-by mode), the two rectangular amber LED units in the display are illuminated at a reduced intensity to provide visual confirmation that the system is operating. The display provides a visual indication of a detected object and its proximity by illuminating one or more LED indicators, beginning with the outer most round amber indicators and moving toward the center of the display as the vehicle gets closer to the object. As the vehicle comes to within about 200 centimeters (about 78.7 inches) of the object, one or both of the inner most rectangular amber LED indicators illuminate at full intensity and the display emits a single half-second audible beep. As the vehicle comes to within about 50 centimeters (19.7 inches) of the object, all of the amber indicators and the first red LED indicator are illuminated and the display emits a series of short, intermittent, audible beeps. If the audio system is turned ON, the audio output will be muted automatically while the park assist audible warning is being generated. The audible warning changes from intermittent beeps to a continuous tone as the final red indicator is illuminated and the vehicle comes to within 30 centimeters (11.8 inches) of a detected object. When the park assist module monitors a problem in any of the park assist system circuits or components, it stores a fault code or Diagnostic Trouble Code (DTC) in its memory circuit, illuminates all four red LED units in the park assist display, sends an electronic message to the EVIC, and a SERVICE PARK ASSIST SYSTEM textual message is displayed in the EVIC display. The hard wired circuits between components related to the park assist system may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the park assist system or the electronic controls or communication between modules and other devices that provide some features of the park assist system. The most reliable, efficient, and accurate means to diagnose the park assist system or the electronic controls and communication related to park assist system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Description and Operation > Chime/Buzzer - Description > Page 8030 Parking Assist Warning Indicator: Description and Operation Park Assist Display - Description DESCRIPTION The park assist display (1) is located in the headliner at the rear of the vehicle, just forward of the upper liftgate opening header. Only the smoked clear plastic display lens (3) is visible on the headliner. The lens prevents the 4 red Light Emitting Diode (LED) units and 12 amber LED units from being clearly visible unless they are illuminated by the electronic circuitry of the display. The remainder of the display including the mounting provisions and the electrical connection are concealed above the headliner. A molded plastic housing with an integral connector receptacle (2) at one end contains and protects the electronic circuitry of the display, including an audible tone transducer and an electronic communication chip. A molded plastic retainer (1) with three integral tabs (2) engages three slots integral to the display housing above the lens. The retainer is installed over the display housing above the headliner substrate to engage and securely lock the display into the opening in the headliner. An arrow and the text REAR are molded into an integral installation tab (3) to ensure correct retainer orientation. The park assist display is serviced only as a complete unit. It cannot be adjusted or repaired. If ineffective or damaged, the entire display unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Description and Operation > Chime/Buzzer - Description > Page 8031 Parking Assist Warning Indicator: Description and Operation Park Assist Display - Operation OPERATION The park assist display provides the vehicle operator with visual feedback by illuminating amber or red Light Emitting Diode (LED) units individually or in unison, and audible feedback by energizing an audible tone transducer on the display electronic circuit board to emit either an intermittent or a continuous tone. While the park assist system is active, the number, position and color of the illuminated LED units as well as the audible signal frequency indicate the relative position and distance of obstacles detected at the rear of the vehicle. The park assist display receives battery current and ground from and is completely controlled by the park assist module. The display also contains an electronic communication chip that allows bi-directional communication to occur with the park assist module over a dedicated serial bus line. The microprocessor in the park assist module completely controls the display outputs, continually monitors the display status, and will store a Diagnostic Trouble Code (DTC) in memory for any monitored fault it detects in the park assist display. The illumination intensity of the LED units is also controlled by the park assist module based upon internal programming and electronic panel lamps dimming messages received over the Controller Area Network (CAN) data bus. When the ignition switch is turned to the ON position, all 16 of the LED units in the display will illuminate in unison for approximately 1 second as a bulb test. This output will be interrupted if the system is active and senses an obstacle. Following the conclusion of the bulb test, when the system is active but no obstacle is detected, the display will indicate system readiness by illuminating the two inner most amber LED units (1) at a reduced intensity. As an obstacle is detected, the outermost amber LED unit (5) on the side of the vehicle where the obstacle was detected will be illuminated at normal intensity and a single short audible tone (one-half second duration) is sounded. Then additional amber LED units (6) will begin illuminating inward (2 or 4) as the obstacle gets closer until, finally, the two red LED units (7) are illuminated. When the final red LED unit (3) is illuminated, the obstacle is approximately 40 centimeters (16 inches) from the rear corner of the vehicle or approximately 50 centimeters (19.7 inches) from the rear bumper face and an intermittent audible tone will be generated. The frequency of the audible tone will increase as the obstacle continues to become closer until the tone is continuous when the obstacle is about 15 centimeters (6 inches) from the rear corner of the vehicle or about 30 centimeters (11.8 inches) from the rear bumper face. Whenever a park assist audible tone is being generated, the park assist module sends electronic messages to the radio over the CAN data bus to mute the audio system. The audible tone will be cancelled after about two seconds if the detected distance to the obstacle remains constant. See the Park Assist Display Outputs table for additional details. The hard wired circuits between components related to the park assist display may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the park assist display or the electronic controls or communication between modules and other devices that provide some features of the park assist system. The most reliable, efficient, and accurate means to diagnose the park assist display or the electronic controls and communication related to park assist display operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Description and Operation > Chime/Buzzer - Description > Page 8032 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Description and Operation > Page 8033 Parking Assist Warning Indicator: Testing and Inspection PARK ASSIST SYSTEM WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. If a SERVICE PARK ASSIST SYSTEM textual message appears in the Electronic Vehicle Information Center (EVIC) display, be certain to confirm the following: - Be certain that the rear bumper is free of dirt and debris to keep the system operating properly. - Be certain that the parking brake is not applied. - The presence of jackhammers, large trucks, and other vibrations in the vicinity of the vehicle could impact the performance of the system. The hard wired circuits between components related to the park assist system may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the park assist system or the electronic controls or communication between modules and other devices that provide some features of the park assist system. The most reliable, efficient, and accurate means to diagnose the park assist system or the electronic controls and communication related to park assist system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Service and Repair > Park Assist Display - Removal Parking Assist Warning Indicator: Service and Repair Park Assist Display - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the trim from the upper liftgate opening. See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal. 3. Remove the trim from both upper D-pillars. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Removal. 4. Carefully pull down the rear edge of the headliner (5) from the upper liftgate opening header (2) far enough to access the rear park assist display housing (3) and the display retainer (4). 5. Disconnect the wire harness connector (1) from the connector receptacle on the left end of the display housing. 6. Carefully spread the front and rear edges of the molded plastic retainer far enough to disengage the three retainer tabs from the slots in the display housing, then lift the retainer off of the display housing. 7. Push the right end of the display out through the lower surface of the headliner, then slide the display toward the right side of the vehicle far enough to disengage the connector receptacle from the headliner opening. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Parking Assist Warning Indicator > Component Information > Service and Repair > Park Assist Display - Removal > Page 8036 Parking Assist Warning Indicator: Service and Repair Park Assist Display - Installation INSTALLATION 1. Carefully position the connector receptacle on the left end of the park assist display housing (3) through the left end of the display opening in the lower surface of the headliner (5). 2. Slide the display toward the left side of the vehicle far enough to engage the right end of the display housing into the right end of the display opening in the headliner. 3. Carefully pull down the rear edge of the headliner from the upper liftgate opening header (2) far enough to access the rear park assist display housing. 4. With the display lens held flush against the lower surface of the headliner, position the molded plastic retainer (4) over the display housing with the installation tab oriented towards the rear of the vehicle. 5. Slide the retainer down over the display housing until it is flash with the headliner substrate and the three tabs of the retainer are engaged in the three slots of the display housing. 6. Reconnect the wire harness connector (1) to the connector receptacle on the left end of the display housing. 7. Reinstall the trim onto both upper D-pillars. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Installation. 8. Reinstall the trim onto the upper liftgate opening. See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal. 9. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Diagrams Rear Vision Camera: Diagrams Connector - (LIFTGATE) 8 WAY CAMERA-REAR VIDEO - (LIFTGATE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Description and Operation > Rear Camera - Description Rear Vision Camera: Description and Operation Rear Camera - Description DESCRIPTION The Rear View Camera (RVC) (4) (also known as ParkView(TM)), is a camera on chip device utilizing Complementary Metal Oxide Semiconductor (CMOS) technology. CMOS technology is used for a wide variety of digital or analog circuits. In this application, it supports the analog image sensor of the RVC. The RVC function is to provide a wide angle video image of the area behind the vehicle, including areas that might not be normally visible from the seated position of the vehicle operator, only while the transaxle gear selector is in the Reverse position. This video image then displays to the vehicle operator within the display screen of the audio system receiver unit near the center of the instrument panel. The RVC is intended to be an auxiliary viewing aid and is not promoted as an obstacle detection or safety device. It does not remove vehicle operator responsibility to recognize and obey official traffic laws or regulations or to take sensible precautions and care to avoid pedestrians, other vehicle traffic or both fixed and moving obstacles through the habitual use of safe and defensive driving techniques. The RVC is located on the underside of the light bar (1) mounted above the license plate tub on the vehicle liftgate. The camera lens is visible just to the left of the vehicle center line, while the body of the camera and the camera connections are concealed within the light bar above a camera mounting bracket (3), to which the camera is secured with three screws. The camera mounting bracket secures to the light bar assembly to the left of the left license plate lamp (2) with two additional screws. A light bar wire harness routes through a rubber grommet into the interior of the liftgate where it connects the RVC and both license plate lamps to the vehicle electrical system through a dedicated take out and connector of the liftgate wire harness. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Description and Operation > Rear Camera - Description > Page 8042 The camera image sensor and electronics are sealed and protected within a two-piece die cast zinc housing (1), held together by four screws (2). The camera lens (5) extends from the lower surface of the housing and an integral connector receptacle (3) containing five terminal pins that extends from the right side of the housing. Additionally, there are three mounting bosses (4) integral to the camera housing, two on the left side and one on the right. The mounting bosses receive the three self-tapping screws securing the unit to the camera bracket. Hardwired circuitry connects the RVC to the electrical system of the vehicle. These hardwired circuits are integral to several wire harnesses, which routes throughout the vehicle and retained by many different methods. These circuits may be connected to each other and to the vehicle electrical system through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. The RVC cannot be adjusted or repaired. If the RVC is damaged or ineffective, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Description and Operation > Rear Camera - Description > Page 8043 Rear Vision Camera: Description and Operation Rear Camera - Operation OPERATION The Rear View Camera (RVC) is powered by a battery feed received through the backup lamp switch output circuit from the Totally Integrated Power Module (TIPM) so that is only active when the transaxle is shifted into the REVERSE position. In addition, the radio receiver monitors messages on the Controller Area Network (CAN) data bus to determine the selected transaxle gear and overrides any other display to show the RVC video output, whenever it detects that the transaxle is in REVERSE. A momentary blank video display screen immediately following the gearshift transition into the REVERSE position is considered normal operation. The camera electronics receive a path to ground at all times through a takeout and eyelet terminal of the liftgate wire harness that is secured by a ground screw to the right side of the liftgate inner panel. The output of the camera is a video signal compatible to the National Television System Committee (NTSC) standard composite video M format, or NTSC-M. The video signal is delivered to the radio video display unit through the entire length of the vehicle by camera signal and the camera return circuits that are arranged as a twisted pair, with an additional grounded foil jacket to protect the video signal from corruption due to stray radiated signals within the vehicle environment. The ground shield is terminated only at the video display (radio) end, not at the camera. Portions of these video signal wires are contained within the liftgate light bar wire harness, the liftgate wire harness, the body wire harness and a jumper harness located between the radio and the body harness connector below the instrument panel at the right cowl side inner panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Rear Vision Camera: Symptom Related Diagnostic Procedures REAR CAMERA INOPERATIVE For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. - When Monitored: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8046 Ignition on, vehicle in reverse. - Set Condition: No rear picture is displayed on radio with the vehicle in reverse. 1. VERIFY OPERATION OF THE RADIO AND BACKUP LAMPS 1. Verify the operation of the Radio and Backup Lamps. Do the Radio and Backup Lamps operate correctly? Yes - Go To 2 No - Diagnose any problems with the Radio and Backup Lamps. - Perform the BODY VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test. 2. (L1) BACKUP LAMP FEED CIRCUIT 1. Turn the ignition off. 2. Apply the parking brake. 3. Disconnect the Rear Video Camera harness connector. 4. Turn the ignition on. 5. Shift the vehicle into reverse. 6. Measure the voltage of the (L1) Backup Lamp Feed circuit. Is battery voltage present? Yes - Go To 3 No Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8047 - Using the wiring diagrams as a guide, repair the (L1) Backup Lamp Feed circuit for an open or short to ground. - Perform the BODY VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test. 3. (Z945) GROUND CIRCUIT 1. Turn the ignition off. 2. Measure the resistance between ground and the (Z945) Ground Circuit. Is the resistance below 10.0 Ohms? Yes - Go To 4 No - Using the wiring diagrams as a guide, repair the (Z945) Ground circuit for an open. - Perform the BODY VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test. 4. CAMERA SIGNAL, RETURN, AND SHIELD CIRCUITS OPEN 1. Disconnect the Radio C3 harness connector. 2. Measure the resistance of the (X970) (X971) and (X972) circuits. Is the resistance below 10.0 Ohms on the (X970) (X971) or (X972) circuits? Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8048 Yes - Go To 5 No - Using the wiring diagrams as a guide, repair the appropriate circuit for an open. - Perform the BODY VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test. 5. CAMERA SIGNAL, RETURN, AND SHIELD CIRCUITS SHORTED TO GROUND 1. Measure the resistance between ground and the (X970) (X971) and (X972) circuits. Is the resistance below 10.0 Ohms on the (X970) (X971) or (X972) circuits? Yes - Using the wiring diagrams as a guide, repair the appropriate circuit for a short to ground. - Perform the BODY VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test. No - Replace the Rear Video Camera. - Perform the BODY VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Body Verification Test. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8049 Rear Vision Camera: Component Tests and General Diagnostics Rear Camera The hardwired circuits of the Rear View Camera (RVC) and those between the RVC and the radio receiver may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the RVC or the radio receiver. The most reliable, efficient and accurate means to diagnose the electronic controls and communication related to radio receiver operation, as well as the retrieval or erasure of a DTC requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: Be certain to confirm both of the following prior to attempting any further diagnosis or testing of the RVC. Use a diagnostic scan tool to confirm the rear view camera is setup in the vehicle configuration. From the initial start up screen of the diagnostic scan tool, navigate to ECU VIEW, select TIPMCGW CENTRAL GATEWAY, MORE OPTIONS, ECU DETAILS and then CONFIG INFO. Verify that REAR CAMERA PRESET - - - SET is present. If not, the Sales Code XAC (Park View Rear Back-Up Camera) will have to be added to the vehicle configuration to enable the RVC, in vehicles equipped with a MyGIG multimedia entertainment system (Sales Codes RE1, REN, REP, RER, REU, REW, REX or REZ), be certain that the RVC is set to ENABLED using the CAMERA SETUP option in the MyGIG system settings. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 8050 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Service and Repair > Rear Camera - Removal Rear Vision Camera: Service and Repair Rear Camera - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the liftgate handle. See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Handle/Service and Repair/Exterior Handle - Removal. 3. Remove the camera mounting bracket. 4. Remove the camera mounting fasteners. 5. Disconnect the electrical harness connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Rear Vision Camera > Component Information > Service and Repair > Rear Camera - Removal > Page 8053 Rear Vision Camera: Service and Repair Rear Camera - Installation INSTALLATION NOTE: Use of oil is recommended when using self tapping screws to install the new camera assembly. 1. Connect the electrical harness connector. 2. Install the camera to the mounting bracket. 3. Install the camera mounting fasteners. 4. Install the liftgate handle. See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Handle/Service and Repair/Exterior Handle - Installation. 5. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations > Page 8057 Vacuum Brake Booster Diaphragm Position Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 3 WAY SENSOR-BOOSTER TRAVEL (HEV) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Description DESCRIPTION The travel sensor (7) is mounted on power brake booster (1) below and to the left of the master cylinder, and has one electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description > Page 8060 Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Operation OPERATION The travel sensor is a three-wire potentiometer that varies the voltage output as the position of the booster diaphragm changes. The RBS module uses the position information to determine the amount of booster movement and hydraulic brake application. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor Removal Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor - Removal REMOVAL 1. Disconnect the electrical connector (2) from the travel sensor (1). NOTE: The retainer clip does not need to be removed, only pushed up slightly to disengage the tabs on the sensor. 2. Using a small screw driver (4) or another suitable tool, push up on the retainer clip (2) and pull the travel sensor (3) from the power brake booster (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor Removal > Page 8063 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor Installation INSTALLATION NOTE: When replacing the travel sensor, the Anti-Lock Brake Module (ABM) must be initialized using the scan tool. To initialize the ABM perform the ABS VERIFICATION TEST - HEV. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test . NOTE: Verify that the surface is clean, the old O-ring is removed, and the new O-ring is properly positioned on the sensor. 1. With a slight twisting motion, push the travel sensor (3) into the power brake booster (1). There should be a slight snapping sound as the retainer clip (3) seats into position. 2. Verify that the travel sensor retainer clip (3) snapped into place. 3. Connect the electrical connector (2) to the travel sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup Driver/Vehicle Information Display: Technical Service Bulletins Instruments - Vehicle Information Center Setup NUMBER: 08-002-09 GROUP: Electrical DATE: February 4, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-014-07, DATED JULY 11, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL YEARS AND MODELS. SUBJECT: Electronic Vehicle Information Center (EVIC) Oil Change Indicator System - Dealer Preferences During Prep MODELS: 2008 (DR) Ram Truck **2009 (HB) Durango** **2009 (HG) Aspen** **2009 (JC) Journey** **2008 - 2009 (KA) Nitro** **2008 - 2009 (KK) Liberty** **2009 (LC) Challenger** **2008 - 2009 (LX) 300 / Magnum / Charger** **2008 - 2009 (RI) Caravan / Town & Country** NOTE: This Bulletin applies to vehicles equipped with a programmable EVIC. DISCUSSION: **Many models now include an oil change indicator system**. This system displays an "Oil Change Required" or "Oil Change" message at appropriate intervals on the instrument cluster. The vehicles listed above may be equipped with a programmable display on the Electronic Vehicle Information Center, (EVIC). The "Oil Change Required message may also include the dealerships name and phone number which can be programmed into the vehicle with the StarSCAN(R) or StarMOBILE(R) scan tool. NOTE: **Other vehicles may be added at any time. Dealers can determine if the feature is available by following the procedures below. If Enable/Disable Dealer Contact Information is active, the feature can be used to enter the servicing dealer's information.** The following procedure describes the steps to add, delete or change a dealership name and phone number on the display. NOTE: If NOT programmed during vehicle prep, customer approval MUST be obtained before adding or changing this information. NOTE: When performing this Procedure, the software release level in the StarSCAN(R) or StarMOBILE(R); must be programmed with the latest level software. The software release level is visible in the blue header at the top of the StarSCAN(R) or StarMOBILE(R) screen. 1. Connect the StarSCAN(R) or StarMOBILE(R). (in Pass-Through Mode) NOTE: To use the StarMOBILE(R) in Pass-Through Mode requires that StarMOBILE(R) be connected to the dealership network via a wired or wireless connection. For more information on how to use the StarMOBILE(R) in Pass-Through Mode, see the StarMOBILE(R) training tutorials available on DealerCONNECT > Service > Repair > StarSCAN(R) and StarMOBILE(R) Tools link or at the website. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup > Page 8068 2. From the Home Screen, enter "ECU VIEW or "VEHICLE PREP". 3. Select "CCN". 4. Select "Misc. Functions". 5. Select "Enable/Disable Dealer Contact Information". 6. Select "Enable" or "Disable" as desired. 7. If enabled, select "Program Dealer Contact Information" and follow on screen prompts. 8. "Reset will cause display to read: "Contact Dealer" as default. 9. Select finish to exit. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 8069 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8072 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8073 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8074 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8075 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8076 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8077 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8078 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8079 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8080 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8081 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8082 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8083 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8084 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8085 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8086 Driver/Vehicle Information Display: Connector Views Connector - (HEADLINER) 6 WAY MODULE-ELECTRONIC OVERHEAD - (HEADLINER) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8087 Driver/Vehicle Information Display: Electrical Diagrams OVERHEAD CONSOLE - Diagram 02 (HANDS FREE) PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8088 Overhead Console 8W-49-01 Overhead Console 8W-49-02 (Hands Free) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8089 Overhead Console 8W-49-03 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8090 Overhead Console 8W-49-04 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 8091 Overhead Console 8W-49-05 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description Driver/Vehicle Information Display: Description and Operation Liftgate Ajar Indicator - Description DESCRIPTION A gate ajar indicator is standard equipment on all instrument clusters. This indicator is located within the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. The gate ajar indicator consists of the text GATE, which appears in place of the odometer/trip odometer information in the odometer VFD unit. However, on vehicles equipped with the optional Electronic Vehicle Information Center (EVIC), an additional International Standards Organization (ISO) symbol for open liftgate is also provided by the EVIC. The odometer VFD is soldered onto the cluster electronic circuit board, and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The gate ajar indicator appears in the same blue-green color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The gate ajar indicator is serviced as a unit with the VFD unit in the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 8094 Driver/Vehicle Information Display: Description and Operation Liftgate Ajar Indicator - Operation OPERATION The gate ajar indicator gives an indication to the vehicle operator that the rear liftgate may be open or not completely latched. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and a hardwired input received by the cluster from the liftgate ajar switch integral to the liftgate latch unit. The gate ajar indicator function of the Vacuum Fluorescent Display (VFD) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the VFD gate ajar indication is always off when the ignition switch is in any position except ON or START. The instrument cluster turns on the gate ajar indicator for the following reasons: - Liftgate Ajar Switch Input - Each time the cluster detects ground on the liftgate ajar switch sense circuit (liftgate ajar switch closed = gate is open or not completely latched) the gate ajar indicator illuminates. The indicator remains illuminated until the liftgate ajar switch sense input to the cluster is an open circuit (liftgate ajar switch open = liftgate fully closed), until the cluster has completed an interior lamps load shed (about five minutes), or until the ignition switch turns to the off position, whichever occurs first. The instrument cluster, also known as the Cab Compartment Node (CCN) continually monitors the liftgate ajar switch to determine the status of the liftgate. For further diagnosis of the liftgate ajar indicator or the instrument cluster circuitry that controls the indicator, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use conventional diagnostic tools and procedures for the hardwired liftgate ajar switch and circuits related to gate ajar indicator operation. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 8095 Driver/Vehicle Information Display: Description and Operation No Bus Indicator - Description DESCRIPTION A no-bus indicator is standard equipment on all instrument clusters. The no-bus indication appears within the fixed segment odometer Vacuum Fluorescent Display (VFD) unit. The odometer no-bus indicator consists of a textual No-BUS message that appears in place of the odometer/trip odometer information. The odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located at the base of the cluster overlay right gauge dial face, (Dodge) or the tachometer dial face (Chrysler). The dark lens over the VFD prevents it from being clearly visible when not illuminated. The no-bus textual message appears in the same blue-green color and at the same lighting level as the other information displayed in the odometer VFD unit when illuminated by the instrument cluster electronic circuit board. During daylight hours, (exterior lamps are off) the odometer VFD unit illuminates at full brightness for clear visibility. At night (exterior lamps are on), the VFD lighting level adjusts with the other cluster illumination lamps using the panel lamps dimmer thumbwheel of the headlamp switch on the instrument panel. However, a Parade mode position of the thumbwheel allows the VFD unit to illuminate at full brightness if the exterior lamps are turned on during daylight hours. The no-bus indicator is serviced as a unit with the odometer VFD unit in the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 8096 Driver/Vehicle Information Display: Description and Operation No Bus Indicator - Operation OPERATION The no-bus indicator gives an indication to the vehicle operator when the electronic communication data bus is ineffective. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and electronic messages not being received over the Controller Area Network (CAN) data bus from the Front Control Module (FCM). The no-bus indicator function of the odometer Vacuum Fluorescent Display (VFD) unit is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the odometer VFD no-bus indicator is always off when the ignition switch is in any position except ON or START. The instrument cluster turns ON the no bus indicator for the following reasons: - No Electronic Communication Messages - Each time the ignition switch is turned to the ON position and the cluster does not receive electronic communication messages over the CAN data bus, the no-bus indicator illuminates. The indicator remains illuminated until CAN bus communication is restored or until the ignition switch turns to the OFF position, whichever occurs first. The instrument cluster, also known as the Cab Compartment Node (CCN) continually monitors the CAN data bus to determine the status of many sensors and systems throughout the vehicle. If bus communication is interrupted, the CCN cannot provide accurate displays and outputs. Use a diagnostic scan tool is required for proper diagnosis of the no-bus indicator, the CCN, the CAN data bus or the electronic communication related to no-bus indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 8097 Driver/Vehicle Information Display: Description and Operation Liftgate Ajar Indicator - Description DESCRIPTION A gate ajar indicator is standard equipment on all instrument clusters. This indicator is located within the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. The gate ajar indicator consists of the text GATE, which appears in place of the odometer/trip odometer information in the odometer VFD unit. However, on vehicles equipped with the optional Electronic Vehicle Information Center (EVIC), an additional International Standards Organization (ISO) symbol for open liftgate is also provided by the EVIC. The odometer VFD is soldered onto the cluster electronic circuit board, and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The gate ajar indicator appears in the same blue-green color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The gate ajar indicator is serviced as a unit with the VFD unit in the instrument cluster. Liftgate Ajar Indicator - Operation OPERATION The gate ajar indicator gives an indication to the vehicle operator that the rear liftgate may be open or not completely latched. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and a hardwired input received by the cluster from the liftgate ajar switch integral to the liftgate latch unit. The gate ajar indicator function of the Vacuum Fluorescent Display (VFD) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the VFD gate ajar indication is always off when the ignition switch is in any position except ON or START. The instrument cluster turns on the gate ajar indicator for the following reasons: Liftgate Ajar Switch Input - Each time the cluster detects ground on the liftgate ajar switch sense circuit (liftgate ajar switch closed = gate is open or not completely latched) the gate ajar indicator illuminates. The indicator remains illuminated until the liftgate ajar switch sense input to the cluster is an open circuit (liftgate ajar switch open = liftgate fully closed), until the cluster has completed an interior lamps load shed (about five minutes), or until the ignition switch turns to the off position, whichever occurs first. The instrument cluster, also known as the Cab Compartment Node (CCN) continually monitors the liftgate ajar switch to determine the status of the liftgate. For further diagnosis of the liftgate ajar indicator or the instrument cluster circuitry that controls the indicator, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use conventional diagnostic tools and procedures for the hardwired liftgate ajar switch and circuits related to gate ajar indicator operation. Refer to the appropriate wiring information. No Bus Indicator - Description DESCRIPTION A no-bus indicator is standard equipment on all instrument clusters. The no-bus indication appears within the fixed segment odometer Vacuum Fluorescent Display (VFD) unit. The odometer no-bus indicator consists of a textual No-BUS message that appears in place of the odometer/trip odometer information. The odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located at the base of the cluster overlay right gauge dial face, (Dodge) or the tachometer dial face (Chrysler). The dark lens over the VFD prevents it from being clearly visible when not illuminated. The no-bus textual message appears in the same blue-green color and at the same lighting level as the other information displayed in the odometer VFD unit when illuminated by the instrument cluster electronic circuit board. During daylight hours, (exterior lamps are off) the odometer VFD unit illuminates at full brightness for clear visibility. At night (exterior lamps are on), the VFD lighting level adjusts with the other cluster illumination lamps using the panel lamps dimmer thumbwheel of the headlamp switch on the instrument panel. However, a Parade mode position of the thumbwheel allows the VFD unit to illuminate at full brightness if the exterior lamps are turned on during daylight hours. The no-bus indicator is serviced as a unit with the odometer VFD unit in the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 8098 No Bus Indicator - Operation OPERATION The no-bus indicator gives an indication to the vehicle operator when the electronic communication data bus is ineffective. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and electronic messages not being received over the Controller Area Network (CAN) data bus from the Front Control Module (FCM). The no-bus indicator function of the odometer Vacuum Fluorescent Display (VFD) unit is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the odometer VFD no-bus indicator is always off when the ignition switch is in any position except ON or START. The instrument cluster turns ON the no bus indicator for the following reasons: - No Electronic Communication Messages - Each time the ignition switch is turned to the ON position and the cluster does not receive electronic communication messages over the CAN data bus, the no-bus indicator illuminates. The indicator remains illuminated until CAN bus communication is restored or until the ignition switch turns to the OFF position, whichever occurs first. The instrument cluster, also known as the Cab Compartment Node (CCN) continually monitors the CAN data bus to determine the status of many sensors and systems throughout the vehicle. If bus communication is interrupted, the CCN cannot provide accurate displays and outputs. Use a diagnostic scan tool is required for proper diagnosis of the no-bus indicator, the CCN, the CAN data bus or the electronic communication related to no-bus indicator operation. Refer to the appropriate diagnostic information. No Fuse Indicator - Description DESCRIPTION A no fuse indicator is standard equipment on all instrument clusters. The no fuse indication appears within the odometer Vacuum Fluorescent Display (VFD) unit. The no fuse indicator consists of a textual noFUSE message which appears in place of the odometer information in the odometer display. The odometer VFD is soldered onto the cluster electronic circuit board, and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The no fuse textual message appears in the same blue-green color and at the same lighting level as the odometer information when it is illuminated by the instrument cluster electronic circuit board. The no fuse indicator is serviced as a unit with the VFD in the instrument cluster. No Fuse Indicator - Operation OPERATION The no-fuse indicator gives an indication to the vehicle operator when the Ignition Off Draw (IOD) fuse is ineffective or is not installed. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Front Control Module (FCM). The no-fuse indicator function of the odometer Vacuum Fluorescent Display (VFD) unit is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the odometer VFD no-fuse indication is always off when the ignition switch is in any position except ON or START. The instrument cluster turns on the no-fuse indicator for the following reasons: - No-Fuse indicator lamp-on message - Each time the ignition switch is turned to the ON position and the cluster receives an electronic no-fuse indicator lamp-on message from the FCM indicating that the IOD fuse is missing or ineffective, the no-fuse indicator illuminates. The indicator remains illuminated for about three seconds, until the IOD fuse installs, until the trip odometer reset switch button pressed or until the ignition switch is turned to the OFF position, whichever occurs first. The FCM continually monitors the IOD circuit to determine the status of the IOD fuse, then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN) over the CAN data bus. Use a diagnostic scan tool is required for proper diagnosis of the no-fuse indicator, the FCM, the CCN, the CAN data bus or the electronic communication related to no-fuse indicator operation. Refer to the appropriate diagnostic information. Service 4WD Indicator - Description Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 8099 DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located below the minor gauge set on the left side of the cluster. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Service 4WD Indicator - Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Front Control Module (FCM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the FCM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-on message from the FCM, the service 4WD indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-off messages from the FCM for 10 seconds, the service 4WD indicator is illuminated by the cluster to indicate a loss of FCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the FCM. - Self Test - Each time the cluster is put through the self test, the service 4WD indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The FCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the FCM, the CCN, the CAN data bus or the electronic communication related to service 4WD indicator operation. Refer to the appropriate diagnostic information. Transmission Temperature Indicator - Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. This indicator is located in the center of the speedometer, in the area above and to the right of the speedometer needle hub. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 8100 The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Transmission Temperature Indicator - Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic transmission over temp indicator lamp-on message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator illuminates and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-off message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature only repeats during the same ignition cycle if the indicator is cycled off and then on again by the appropriate lamp-on and lamp-off messages from the PCM. - Self Test - Each time the cluster is put through the self test, the transmission over temperature indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the instrument cluster illuminates the transmission over temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transmission temperature sensor, the PCM, the CCN, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation. Refer to the appropriate diagnostic information. Electronic Vehicle Information Center - Description DESCRIPTION NOTE: The Electronic Vehicle Information Center (EVIC) module is sometimes referred to as Electronic Overhead Module (EOM) for the purposes of scan tool and diagnostic information naming. Please treat the EVIC and EOM as one and the same when diagnosing the vehicle. The Electronic Vehicle Information Center (EVIC) is located in the overhead console and consists of the following components: - HomeLink(R) transceiver (3) - if equipped - Vacuum-Fluorescent Display (VFD) (6) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 8101 - Push button function switches (1, 2, 3, 4 and 5) - Replaceable light bulbs to illuminate the push button function switches This system conveniently allows the driver to select a variety of useful information by pressing the function buttons. The EVIC displays information related to the following: - System status - Vehicle information warning message displays - Tire Pressure Monitor System (TPM) - If Equipped - Personal settings (customer programmable features) - Compass display - Outside temperature display - Trip computer functions The EVIC system is comprised of several different components. Those components are: - Instrument Cluster also known as Cab Compartment Node (CCN). - Ambient Temperature Sensor - EVIC Module - Controller Area Network (CAN) Data Bus circuit The only serviceable components of the EVIC module are the push button illumination bulbs, See: Service and Repair/Removal and Replacement/Electronic Vehicle Information Center - Removal. All other components of the EVIC module are not serviced separately and if damaged or inoperative, must be replaced as a unit. Electronic Vehicle Information Center - Operation OPERATION The Electronic Vehicle Information Center (EVIC) uses both non-switched and ignition switched sources of battery current so that some of its features remain operational at any time, while others may only operate with the ignition switch in the On position. When the ignition switch is turned to the On position, the EVIC display will return to the last function being displayed before the ignition was turned to the Off position. The EVIC system is comprised of several different components that communicate over the Controller Area Network (CAN) Data Bus. If the system is inoperative a scan tool and the appropriate diagnostic information must be used to diagnose the system. The EVIC push buttons are used to operate the different functions of the EVIC system. Pressing and releasing the MENU button (1) will change the mode displayed to one of the Personal Settings. The STEP button (2) is used to make a selection from the Personal Settings displayed at that time. Pressing and releasing the C/T (compass/temperature) button (5) will cause the EVIC to return to the compass/temperature/trip computer display mode from any other mode. From the compass/temperature/trip computer display mode the STEP button (2) is used to scroll through and make selections in the Trip Functions. Pressing and releasing the RESET button (4) resets the trip computer screen displayed at that time. EVIC DISPLAY MODES SYSTEM STATUS MODE Displays warnings and user interaction messages. Critical text warnings will be displayed until the failure is corrected. Non-critical text warnings will be displayed for 60 seconds. The driver can scroll to view multiple messages by using the STEP button. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 8102 When the appropriate conditions exist, the EVIC displays the following messages: - TURN SIGNALS ON (with a continuous warning chime) - RKE BATTERY LOW (with a single chime) - PERSONAL SETTINGS NOT AVAILABLE - Vehicle Not in Park - LEFT/RIGHT FRONT DOOR AJAR (one or more, with a single chime if speed is above 1 mph) - LEFT/RIGHT REAR DOOR AJAR (one or more, with a single chime if speed is above 1 mph) - DOOR(S) AJAR (with a single chime if vehicle is in motion) - LOW WASHER FLUID (with a single chime) - SERVICE PARK ASSIST SYSTEM (with a single chime) - OIL CHANGE REQUIRED (with single chime) - LEFT FRONT TURN LAMP OUT - RIGHT FRONT TURN LAMP OUT - LEFT REAR TURN LAMP OUT - RIGHT REAR TURN LAMP OUT - SERVICE PARK ASSIST SYSTEM - COOLANT LOW - ESP SYSTEM DEACTIVATED - LIFTGATE OPEN PERSONAL SETTINGS MODE (CUSTOMER PROGRAMMABLE FEATURES) Allows the driver to set and recall features when the transmission is in PARK by pressing and releasing the MENU button until Personal Settings is displayed in the EVIC. If the transmission is not in PARK the EVIC will display NOT AVAILABLE and VEHICLE NOT IN PARK. The following personal settings can be set and recalled by pressing the STEP button: - "LANGUAGE" - When in this display you may select one of three languages for all display nomenclature, including the trip functions. Press the RESET button while in this display to select English, Espanol, or Francais. Then, as you continue, the information will display in the selected language. - "AUTO DOOR LOCKS > YES" - When ON is selected, all doors will lock automatically when the vehicle reaches a speed of 15 mph (24 km/h). To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "AUTO UNLOCK ON EXIT > YES" - When ON is selected, all doors will unlock when the vehicle is stopped and the transmission is in the P (Park) or N (Neutral) position and the driver's door is opened. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "RKE UNLOCK DRV DR 1st" - When DRV DR 1st is selected, only the driver's door will unlock on the first press of the remote keyless entry unlock button. When Driver Door 1st Press is selected, you must press of the remote keyless entry unlock button twice to unlock the passenger's doors. To make your selection, press and release the RESET button until "DRV DR 1st " appears. - "RKE UNLOCK ALL DR 1ST" - When All ALL DR 1ST is selected, all of the doors will unlock on the first press of the remote keyless entry unlock button. To make your selection, press and release the RESET button until "All DR 1st" appears. - "MEM RECALL WITH RKE > YES" - When ON is selected, pressing the unlock button on the RKE will recall the memory settings for the seat, mirror and radio. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "SOUND HORN W/LOCK > YES" - When ON is selected, a short horn sound will occur when the remote keyless entry "Lock" button is pressed. This feature may be selected with or without the flash lights on lock/unlock feature. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "FLASH LAMPS w/LOCK > YES" - When ON is selected, the front and rear turn signals will flash when the doors are locked or unlocked with the remote keyless entry transmitter. This feature may be selected with or without the sound horn on lock feature selected. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "HEAD LAMP OFF DELAY > 0 SEC" - When this feature is selected, the driver can choose to have the headlights remain on for 0, 30, 60, or 90 seconds when exiting the vehicle. To make your selection, press and release the RESET button until "0," "30," "60," or "90" appears.NOTE: The head lamp switch must be in the "A" auto mode for this feature to work. - HEADLAMPS W /WIPERS > YES - When ON is selected, the headlamps will automatically turn on when the wiper switch is activated. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - EASY EXIT SEAT > YES - When ON is selected, and the key is removed from the ignition, the driver's seat will automatically move rearward to allow easy exit. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - TILT MIRRORS IN "R" > YES - When On is selected, and the transmission is put in reverse, the outside mirrors will tilt downward. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "KEY OFF POWER DELAY > OFF" - When this feature is selected, the power window switches, radio, hands-free system (if equipped), DVD video system (if equipped) and power outlets will remain active for up to 60 minutes after the ignition switch is turned off. Opening a vehicle door will cancel this feature. To make your selection, press and release the RESET button until "Off," "45 sec.," "5 min.," "10 min." appears. - "ILLUMINATED APRCH > OFF" - When this feature is selected, the headlights will activate and remain on for up to 90 seconds when the doors are unlocked with the remote keyless entry transmitter. To make your selection, press and release the RESET button until "OFF," "30 sec.," "60 sec.," or "90 sec." appears. - PARK ASST. SYSTEM > YES - When YES is selected, the Park Assist System is activated when the vehicle is in Reverse. When No is selected, the Rear Park System is turned off. To make your selection, press and release the RESET button until "ON" or "OFF" appears. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 8103 - "UNIT IN > US/METRIC" - The EVIC, odometer can be changed between English and Metric units of measure. To make your selection, press and release the RESET button until "US" or "METRIC" appears. - "COMPASS VARIANCE > 1" - Press the RESET button to change the compass variance setting. See: Adjustments for additional information. - "COMPASS CALIBRATE > YES" - Press the RESET button to calibrate the compass. See: Adjustments for additional information. COMPASS/TEMPERATURE/TRIP COMPUTER MODE This display provides the outside temperature, one of the eight compass headings to indicate the direction the vehicle is facing, and vehicle trip information. The compass and temperature display is the normal display. When the C/T button is pressed the EVIC returns to the compass/temperature display from all other functions. The trip computer function will be displayed if the STEP button is pressed from the Compass/Temperature display mode. The trip computer displays the following information: - TRIP - Shows the total distance traveled since the last reset. To reset the TRIP function, press and hold the RESET button. - ELAPSED TIME - Shows the total elapsed time of travel since the last reset. Elapsed time will increment when the ignition switch is in the ON/RUN or START positions. - UNIT IN US/METRIC - Press the RESET button to toggle between US and METRIC. - AVG. MPG - Shows the average fuel economy since the last reset. When the fuel economy is reset, the display will show dashes for two seconds. Then the history information will be erased, and the averaging will continue from the last fuel average reading before the reset. (Example: If your Electronic Vehicle Information Center (EVIC) displays 18 AVG. MPG and the RESET button is pressed, the previous averaging history will be erased and the display will return to the 18 AVG. MPG, not to 0 AVG. MPG). The display may take several miles for the value to change dependent upon driving habits. - MI TO EMPTY (Distance To Empty) - Shows the estimated distance that can be traveled with the fuel remaining in the tank. This estimated distance is determined by a weighted average of fuel economy, according to the current fuel tank level. Distance MI TO EMPTY cannot be reset through the RESET button. When the DTE value is less than 30 miles (48 km) estimated driving distance, the DTE display will change to a text display of "LOW FUEL." This display will continue until the vehicle runs out of fuel. Adding a significant amount of fuel to the vehicle will turn off the "LOW FUEL" text and a new DTE value will display. UNIVERSAL GARAGE DOOR (HOMELINK(R)) TRANSCEIVER The EVIC features a driver-interactive display which includes HomeLink(R) system messages. For additional information on the HomeLink(R) transceiver See: Garage Door Opener Transmitter/Description and Operation/Universal Transmitter - Description. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 8104 Driver/Vehicle Information Display: Testing and Inspection ELECTRONIC VEHICLE INFORMATION CENTER The Electronic Vehicle Information Center (EVIC) data is obtained from several components on the Controller Area Network (CAN) data bus circuit. The EVIC will not function properly if the bus messages from any of these components is not received. If no EVIC data is displayed, check the CAN data bus circuit communications, the instrument cluster also known as Cab Compartment Node (CCN) functions and the Integrated Power Module (IPM). If the problem with the EVIC is an inaccurate or scrambled display, refer to theSELF- DIAGNOSTIC TEST. If the problem with the EVIC is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a scan tool and the proper diagnostic procedures information to test for the correct dimming message inputs being received from the CCN or TIPM over the CAN data bus circuit. If the problem is a no-display condition, use the following procedure. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and harness connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console from the headliner. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 2. Inspect the Ignition Off Draw (IOD) fuse in the IPM. If the IOD fuse is ok and in place, go to 3. If not ok, repair the open IOD fuse circuit as required. 3. Check for battery voltage at the overhead console electrical connector. If ok, go to 4. If not ok, check for battery voltage at the appropriate B(+) fuse in the IPM. Repair the open fused B(+) circuit as required. 4. Turn the ignition switch to the On position. Check the fused ignition switch output circuit(s) at the overhead console electrical connector. If ok, go to 5. If not ok, repair the open or shorted circuit as required. 5. Turn the ignition switch to the Off position. Disconnect and isolate the negative battery cable. Check for continuity between the ground circuit cavity of the overhead console electrical connector and a good ground. There should be continuity. If ok, refer to theSELF- DIAGNOSTIC TEST for further diagnosis of the EVIC module and the CAN data bus circuit. If not ok, repair the open ground circuit as required. SELF- DIAGNOSTIC TEST NOTE: The EVIC Self-Test can also be performed using a scan tool. Navigate to the Auto Self-Test screen under System Tests of the scan tool and initiate the EVIC Self-Test. A self-diagnostic test is used to determine that the EVIC is operating properly electrically. Initiate the self-diagnostic test as follows: 1. With the ignition switch in the Off position, simultaneously press and hold the STEP and RESET buttons while rotating the ignition switch to the Run/On position. 2. Continue to hold both buttons pressed until the EVIC enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the EVIC performs the following checks: Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Status - Compass Status - DC Status - CAN Data Bus Communications Status NOTE: If the EVIC module is equipped with the universal transmitter (also known as HomeLink(R)), the module also checks HomeLink(R) communication test status. 3. Following completion of these tests, the EVIC displays one of two messages: "Self Test: FAIL" or "Self Test: PASS." In addition to the FAIL/PASS message the EVIC displays the current software version (SW V xx.xx.xxx) below the FAIL/PASS info. Press the RESET or STEP button to exit and enter normal mode. Respond to these test results as follows: If no test result message displays, but EVIC operation is still improper, Use a scan tool and the proper diagnostic procedures information are required for further diagnosis. - If the "Self Test: FAIL" message displays, the EVIC is inoperative and must be replaced. - If the "Self Test: PASS" message displays, the EVIC is ok, no faults are present. - If any VFD segment does not light during the display segment test, the EVIC is inoperative and must be replaced. If the first seven tests pass, the EVIC verifies that all the required CAN bus messages are present on the CAN bus. If all required messages are present on the CAN bus, the EVIC automatically returns to normal operation after sixty seconds. The EVIC can also be returned to normal operation anytime during the test by pressing the STEP, C/T, RESET or US/M buttons. NOTE: Pressing the STEP or RESET buttons during any portion of the EVIC Self - Diagnostic Test procedure causes the EVIC to exit diagnostics Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 8105 and return to compass/temperature mode. NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variance adjustment. This procedure allows the compass unit to accommodate variations in the earths magnetic field strength based on geographic location. NOTE: If the compass reading blanks out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Check for stored Diagnostic Trouble Codes (DTCs) and follow the proper diagnostic procedures information as needed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration Driver/Vehicle Information Display: Adjustments Manual Compass Calibration MANUAL COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the overhead console. Do not use magnetic tools when servicing the overhead console. NOTE: Whenever the compass is calibrated manually, the variance number must also be reset. See: for the appropriate procedure. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or the Electronic Vehicle Information Center (EVIC) displays "CAL", perform the following manual calibration procedure. Also, any time EVIC service replacement components are installed, they must be calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. Calibrate the compass manually as follows: 1. Turn the ignition switch to the On/Run position. Press and release the MENU push button (1) until "Personal Settings" is displayed. 2. Press the STEP push button (2) until "Calibrate Compass YES" is displayed. 3. Momentarily depress and release the RESET push button (4) to initiate the calibration procedure. The message "CAL will appear in the Compass/Temperature display. 4. Slowly drive the vehicle on a level surface, away from large metal objects and power lines, through one or two complete circles not exceeding 8 km/h (5 mph). The "CAL" message will disappear from the display to indicate that the compass is now calibrated. NOTE: A blank compass display indicates that vehicle degaussing (demagnetizing) may be necessary. NOTE: If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the EVIC is inoperative. Attempt the calibration procedure at least one more time before performing EVIC diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the manual calibration procedure in another location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration > Page 8108 Driver/Vehicle Information Display: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Variance Settings Map Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. NOTE: If the vehicle is taken on long trips into a new variance zone the compass function may be effected. Compass variance may need to be adjusted to the new zone number to function properly. NOTE: The default for the compass variance from the factory is 8. To set the compass variance: 1. Using the Variance Settings Map, find your geographic location and note the zone number. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration > Page 8109 2. Turn the ignition switch to the On/Run position. Press and release the MENU push button (1) until "Personal Settings" is displayed. 3. Press the STEP push button (2) until "Compass Variance" is displayed. 4. Momentarily depress and release the RESET push button (4) to toggle through the zone numbers (1-15), until the zone number for your geographic location appears in the display. 5. Momentarily depress and release the C/T push button (5) to enter the displayed zone number into the compass unit memory. 6. Confirm that the correct directions are now indicated by the compass. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 3. Slowly approach the head of the overhead console forward mounting screw with the degaussing tool connected. 4. Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. 5. With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is at least 61 centimeters (2 feet) from the screw head, disconnect the tool. To demagnetize the roof panel proceed as follows: 6. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 7. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 8. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 9. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 10. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 11. Calibrate the compass and adjust the compass variance, See: Instrument Panel, Gauges and Warning Indicators/Compass/Adjustments/Compass Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 8112 Variance Adjustment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 8113 Driver/Vehicle Information Display: Removal and Replacement Electronic Vehicle Information Center - Removal ELECTRONIC VEHICLE INFORMATION CENTER 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the headliner, See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Remove the screws (1) that secure the Electronic Vehicle Information Center (EVIC) (2) to the overhead console housing (3). 4. Remove the EVIC from the overhead console housing. Electronic Vehicle Information Center - Installation ELECTRONIC VEHICLE INFORMATION CENTER NOTE: If a new Electronic Vehicle Information Center (EVIC) has been installed, the compass will have to be calibrated and the variance set. See: Adjustments and See: Adjustments for the appropriate procedures. 1. Position the Electronic Vehicle Information Center (EVIC) (2) onto the overhead console housing (3). 2. Install the screws (1) that secure the EVIC (2) to the overhead console housing (3). Tighten the screws to 2 Nm (20 in. lbs.). 3. Install the overhead console onto the headliner, See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console Installation. 4. Reconnect the battery negative cable. Electronic Vehicle Information Center Control Bulb - Removal BULB - EVIC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 8114 attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: There are provisions for up to four bulb/bulb holder units on the Electronic Vehicle Information Center (EVIC) circuit board. The two outboard bulbs illuminate the EVIC push buttons, while the two center bulbs illuminate the optional universal transmitter push buttons. Therefore, the center bulb locations are only populated on vehicles equipped with the optional universal transmitter. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (1) from the headliner. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Use a small thin-bladed screwdriver to rotate the bulb holder (3) counterclockwise about 30 degrees to unlock it from the keyed opening in the Electronic Vehicle Information Center (EVIC) unit (2) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. Electronic Vehicle Information Center Control Bulb - Installation BULB - EVIC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: There are provisions for up to four bulb/bulb holder units on the Electronic Vehicle Information Center (EVIC) circuit board. The two outboard bulbs illuminate the EVIC push buttons, while the two center bulbs illuminate the optional universal transmitter push buttons. Therefore, the center bulb locations are only populated on vehicles equipped with the optional universal transmitter. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 8115 1. Align the bulb holder and bulb (3) with the keyed opening in the circuit board of the Electronic Vehicle Information Center (EVIC) (2). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the overhead console (1) onto the headliner. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Installation. 5. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 8116 Driver/Vehicle Information Display: Tools and Equipment ELECTRONIC VEHICLE INFORMATION CENTER Degaussing Tool 6029 Radio Frequency Detector 9001 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Antenna, TV > Component Information > Service and Repair > Satellite Video Antenna Mast - Removal Antenna, TV: Service and Repair Satellite Video Antenna Mast - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Lower the front headliner. See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Removal. 3. Disconnect the electrical connectors. 4. Remove the mounting fastener and remove the antenna. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Antenna, TV > Component Information > Service and Repair > Satellite Video Antenna Mast - Removal > Page 8122 Antenna, TV: Service and Repair Satellite Video Antenna Mast - Installation INSTALLATION 1. Install the antenna and mounting fastener. 2. Connect the electrical connectors. 3. Install the headliner. See: Body and Frame/Interior Moulding / Trim/Headliner/Service and Repair/Headliner Installation. 4. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Auxiliary Input / Output Jack, Entertainment System > Component Information > Diagrams Auxiliary Input / Output Jack: Diagrams Connector - (CENTER CONSOLE) 8 WAY PORT-AUXILIARY AUDIO VIDEO - (CENTER CONSOLE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Video Screen Module C1 (Headliner) 22 Way Television / Monitor: Diagrams Video Screen Module C1 (Headliner) 22 Way Connector C1 - (HEADLINER) 22 WAY MODULE-VIDEO SCREEN - (HEADLINER) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Video Screen Module C1 (Headliner) 22 Way > Page 8131 Television / Monitor: Diagrams Video Screen Module C2 (Headliner) 10 Way Connector C2 - (HEADLINER) 10 WAY MODULE-VIDEO SCREEN - (HEADLINER) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Television / Monitor > Component Information > Diagrams > Video Screen Module C1 (Headliner) 22 Way > Page 8132 Television / Monitor: Diagrams Video Screen Module C3 (Headliner) 22 Way Connector C3 - (HEADLINER) 22 WAY MODULE-VIDEO SCREEN - (HEADLINER) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Entertainment System - Disabling Front Seat Video Source DVD Player: Technical Service Bulletins Entertainment System - Disabling Front Seat Video Source NUMBER: 08-004-10 GROUP: Electrical DATE: March 2, 2010 THIS BULLETIN SUPERSEDES SERVICE BULLETIN 08-002-2007 DATED FEBRUARY 6, 2007. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Radio Video Disable Update MODELS: 2010 (D1) Ram Truck (3500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2009 - 2010 (DS) Ram Truck (1500) 2008 - 2009 (HB) Durango 2008-2009 (HG) Aspen 2008-2010 (JC) Journey 2007 - 2010 (JK) Wrangler 2007 - 2010 (JS) Sebring/Avenger/Sebring Convertible 2007-2010 (KA) Nitro 2008-2010 (KK) Liberty 2008 - 2010 (LC) Challenger 2008 - 2010 (LX) 300/ 300C, Charger 2009-2010 (MK) Patriot 2008-2010 (ND) Dakota 2008-2010 (PM) Caliber 2008 - 2010 (RT) Town & Country/Grand Caravan 2008 - 2010 (WK) Grand Cherokee 2008 - 2010 (XK) Commander NOTE: This bulletin applies to vehicles equipped with a Hard Drive Radio (sales code REN, RER, REU, RBZ, RHR). NOTE: Refer to Warranty Bulletin D-07-04 for additional information and a listing of affected states. DISCUSSION: Due to certain state regulations, a function for disabling the front seat video option has been incorporated into the vehicle. This function will enable or disable the radio's ability to play video in the front seat. If enabled, the radio will play video when the vehicle is in Park (Automatic Transmission) or when the parking brake is set and vehicle speed is zero (Manual Transmission). If disabled the radio will NOT play video in the front seat in any operating mode. If it becomes necessary to disable the front seat video option, use the following procedure. NOTE: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > DVD Player > Component Information > Technical Service Bulletins > Entertainment System - Disabling Front Seat Video Source > Page 8137 Using the wiTECH Diagnostic Application for flashing an ECU is made available through the wiTECH Diagnostic Application. For instructions select the "HELP" tab on upper portion of the wiTECH window, then "HELP CONTENTS." This will open the Welcome to wiTECH Help screen were help topics can now selected. 1. Connect the wiTech 2. From the Home Screen select Radio 3. Select "Misc. Functions" 4. Select "Enable/Disable Front Seat Video" 5. Select "Enable" or "Disable" as required by your state laws. 6. Select finish to exit. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C1 (Headliner) 16 Way Entertainment System Control Module: Diagrams Satellite Video Module C1 (Headliner) 16 Way Connector C1 - (HEADLINER) 16 WAY MODULE-SATELLITE VIDEO - (HEADLINER) 16 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C1 (Headliner) 16 Way > Page 8142 Entertainment System Control Module: Diagrams Satellite Video Module C2 (Body Left) 2 Way Connector C2 - (BODY LEFT) 2 WAY MODULE-SATELLITE VIDEO - (BODY LEFT) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C1 (Headliner) 16 Way > Page 8143 Entertainment System Control Module: Diagrams Satellite Video Module C3 (Body Left) 2 Way Connector C3 - (BODY LEFT) 2 WAY MODULE-SATELLITE VIDEO - (BODY LEFT) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C1 (Headliner) 16 Way > Page 8144 Entertainment System Control Module: Diagrams Satellite Video Module C4 (Body) 2 Way Connector C4 - (BODY) 2 WAY MODULE-SATELLITE VIDEO - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Description and Operation > Satellite Video Module - Description Entertainment System Control Module: Description and Operation Satellite Video Module Description DESCRIPTION The satellite receiver module is located above the headliner near the rear liftgate opening. It is mounted to the roof panel with three mounting fasteners. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Description and Operation > Satellite Video Module - Description > Page 8147 Entertainment System Control Module: Description and Operation Satellite Video Module Operation OPERATION The satellite receiver module receives signals from the roof mounted antenna and processes this information before it is sent to the radio. The module operates on both battery feed circuits and CAN bus messages. It will operate with the ignition key in the run or accessory position only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Service and Repair > Satellite Video Module - Removal Entertainment System Control Module: Service and Repair Satellite Video Module - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Lower the headliner as necessary. 3. Remove the mounting bracket fasteners. 4. Disconnect the antenna and electrical harness connectors. 5. Remove the module from the mounting bracket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Entertainment System Control Module > Component Information > Service and Repair > Satellite Video Module - Removal > Page 8150 Entertainment System Control Module: Service and Repair Satellite Video Module - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Connect antenna and electrical harness connector to module. 2. Install module to mounting bracket. Tighten mounting fasteners. 3. Position module and bracket. Install new mounting fasteners. 4. Install headliner. 5. Connect battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation > Universal Transmitter - Description Garage Door Opener Transmitter: Description and Operation Universal Transmitter - Description DESCRIPTION NOTE: The Electronic Vehicle Information Center (EVIC) module is sometimes referred to as the Electronic Overhead Module (EOM) for the purposes of scan tool and diagnostic information naming. Please treat the EVIC and EOM as one and the same when diagnosing the vehicle. The HomeLink(R) transceiver is integral to the Electronic Vehicle Information Center (EVIC) module located in the overhead console. The only visible component of the HomeLink(R) transceiver are the three transmitter push buttons (3). The buttons are marked with one, two or three dots, respectively, for identification of each channel. Each of the three HomeLink(R) transceiver push buttons controls an independent radio transceiver channel. Each of these three channels can be trained to transmit a different radio frequency signal for the remote operation of garage door openers, motorized gate openers, home or office lighting, security systems or just about any other device that can be equipped with a radio receiver in the 286 to 399 MegaHertz (MHz) frequency range for remote operation. The HomeLink(R) transceiver is capable of operating systems using either rolling code or non-rolling code technology. The HomeLink(R) transceiver cannot be repaired, and is available for service only as part of the EVIC module. This unit includes the push button switches for both the transceiver (3) and EVIC (1, 2, 4 and 5) as well as the vacuum-fluorescent display (6) and the plastic module case. See: Driver/Vehicle Information Display/Service and Repair/Removal and Replacement/Electronic Vehicle Information Center - Removal for replacement procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Description and Operation > Universal Transmitter - Description > Page 8155 Garage Door Opener Transmitter: Description and Operation Universal Transmitter - Operation OPERATION The HomeLink(R) transceiver receives battery feed through the Ignition Off Draw (IOD) fuse circuit of the vehicle. It operates on a non-switched source of battery current so the unit will remain functional, regardless of the ignition switch position. It can learn and store three separate transceiver radio frequency codes to operate garage door openers, security gates and security lighting. The Electronic Vehicle Information Center (EVIC) display provides visual feedback to the driver, showing which transceiver button is pressed. The system will not send operating signals if the vehicle theft security alarm is armed. This prevents a perpetrator from breaking into a vehicle parked outside a home and using the HomeLink(R) transceiver system to enter the home. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics Garage Door Opener Transmitter: Component Tests and General Diagnostics HOMELINK(R) TRANSCEIVER RADIO FREQUENCY DETECTOR #9001 If the HomeLink(R) transceiver is inoperative, but the Electronic Vehicle Information Center (EVIC) Vacuum-Fluorescent Display (VFD) is operating normally, See: Programming and Relearning for instructions on training the HomeLink(R) transceiver. Retrain the HomeLink(R) transceiver with a known good hand held transmitter as instructed and test the HomeLink(R) transceiver operation again. If the unit is still inoperative, test it with the radio frequency detector special tool 9001 as described below: 1. Press the power button (3) and turn the Radio Frequency (RF) detector on. A "chirp" will sound and the green power Light Emitting Diode (LED) indicator will light (2). If the green LED does not light, replace the battery (4). 2. Hold the RF detector within one inch of the TRAINED HomeLink(R) transceiver and press any of the transceiver buttons. 3. The red signal detection LEDs (1) lights and the tool beeps if a radio signal is detected. Repeat this test for each button. If any button is inoperative, replace the EVIC module. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire harness and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 8158 Garage Door Opener Transmitter: Programming and Relearning Programming Homelink(R) Transceiver Codes PROGRAMMING HOMELINK(R) TRANSCEIVER CODES Programming Common HomeLink(R) Transmitter Codes WARNING: Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the transceiver. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: Your motorized door or gate may open and close while you are training the HomeLink(R) Transceiver if the vehicle is in range of the motorized device. Do not train the HomeLink(R) transceiver if people or pets are in the path of the door or gate. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: When programming a garage door opener, it is advised to park outside the garage. It is also recommended that a new battery be placed in the hand held transmitter of the device being programmed to HomeLink(R) for quicker training and accurate transmission of the radio frequency signal. NOTE: If programing the HomeLink(R) transceiver is unsuccessful using the following procedure, Refer to the current customer assistance phone number. - Press and hold the two outer HomeLink(R) transceiver buttons, the EVIC will display "CLEARING CHANNELS" , do not release the buttons until "CHANNELS CLEARED" is displayed on the EVIC (after approximately 20 seconds). Do not hold the buttons for longer than 30 seconds and do not repeat step one to program a second and/or third hand held transmitter to the remaining two HomeLink(R) transceiver buttons. The HomeLink(R) transceiver is now in the train (or learning) mode - Position the end of your hand held transmitter 3-8 cm (1-3 inches) away from the HomeLink(R) transceiver buttons while keeping the EVIC display in view. - Simultaneously press and hold both the HomeLink(R) transceiver button that you want to train and the hand held transmitter button. Do not release the buttons until step 4 has been completed. The EVIC will display "CHANNEL X TRAINING", once the HomeLink(R) transceiver is programmed the EVIC will display "CHANNEL X TRAINED". X refers to the desired channel being trained (1,2 or 3).NOTE: Some gate operators and garage door openers may require you to replace this Programming Step 3 with procedures noted in the Gate Operator/Canadian Programming section. - Once "CHANNEL X TRAINED" is displayed on the EVIC, release both buttons. Programming is now complete. When the HomeLink(R) transceiver button is subsequently pressed, "CHANNEL X TRANSMIT" is displayed on the EVIC and your device should be activated, (garage door should open).NOTE: To program the remaining two buttons, begin with "Programming" step 2. Do not repeat step 1. If the EVIC display shows "CHANNEL X TRANSMIT" (where X is channel 1,2 or 3) but your device does not activate, the device may be equipped with a rolling code system. Continue with the following steps five through seven to complete the programming of a rolling code equipped device (most commonly a garage door opener manufactured after 1995). The assistance of a second person may make the following programming steps quicker and easier. - At the garage door opener receiver (motor head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor head unit. - Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.)NOTE: There are 30 seconds in which to initiate step 8. - Return to the vehicle and firmly press and hold for two seconds then release the programmed HomeLink(R) transceiver button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the programming. The HomeLink(R) transceiver should now activate your rolling code equipped device. NOTE: To program the remaining two HomeLink(R) transceiver buttons, begin with "Programming" step 2. Do not repeat step 1. Canadian Programming/Gate Programming Canadian radio frequency laws require transmitter signals to "time-out" (or quit) after several seconds of transmission which may not be long enough for the HomeLink(R) transceiver to pick up the signal during programming. Similar to this Canadian law, some U.S. gate operators are designed to "time-out" in the same manner. If you live in Canada or you are having difficulties programming a gate operator by using the "Programming" procedures (regardless of where you live), replace programming common HomeLink(R) transceiver codes step 3 with the following: NOTE: When programming a garage door opener or gate operator, it is advised to unplug the device or move the vehicle out of range during Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 8159 the "cycling" process to prevent possible overheating. - 3. Continue to press and hold the HomeLink(R) transceiver button while you press and release every two seconds ("cycle") your hand held transmitter until the frequency signal has successfully been accepted. The EVIC will display "CHANNEL X TRAINING" and then "CHANNEL X TRAINED". Proceed with "Programming" step 4 to complete. Erasing Homelink(R) Transceiver Codes ERASING HOMELINK(R) TRANSCEIVER CODES NOTE: Individual channels cannot be erased. Erasing the HomeLink(R) transceiver codes will erase ALL programmed codes. To erase programming from all three buttons (individual buttons cannot be erased but can be "reprogrammed"), follow the step noted: - Press and hold the two outer HomeLink(R) transceiver buttons until the Electronic Vehicle Information Center (EVIC) displays "CLEARING CHANNELS" , do not release the buttons until "CHANNELS CLEARED" is displayed on the EVIC (after approximately 20 seconds). Release both buttons. Do not hold for longer that 30 seconds. HomeLink(R) is now in the train (or learning) mode and can be programmed at any time beginning with "Programming" See: . Reprogramming Homelink(R) Transmitter Codes REPROGRAMMING HOMELINK(R) TRANSCEIVER CODES Reprogramming Basic HomeLink(R) Transceiver Codes WARNING: Vehicle exhaust contains carbon monoxide, a dangerous gas. Do not run the vehicle's exhaust while training the HomeLink(R) transceiver. Failure to follow these instructions may result in possible serious or fatal injury. WARNING: Your motorized door or gate may open and close while you are training the HomeLink(R) Transceiver if the vehicle is in range of the motorized device. Do not train the HomeLink(R) transceiver if people or pets are in the path of the door or gate. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: If programing the HomeLink(R) transceiver is unsuccessful using the following procedure, Refer to the current customer assistance phone number. To program a device to the HomeLink(R) transceiver using a button previously trained, follow these steps: - Press and hold the desired HomeLink(R) transceiver button. Do Not release the button. The EVIC will display "CHANNEL X TRANSMIT" for 20 seconds and then change to "CHANNEL X TRAINING". Without releasing the HomeLink(R) transceiver button, proceed to step 2. - Position the end of your hand held transmitter 3-8 cm (1-3 inches) away from the HomeLink(R) transceiver button while keeping the EVIC display in view. - Simultaneously press and hold both the HomeLink(R) transceiver button that you want to train and the hand held transmitter buttons. Do not release the buttons until step 4 has been completed. The EVIC will display "CHANNEL X TRAINING", once the HomeLink(R) transceiver is programmed the EVIC will display "CHANNEL X TRAINED". X refers to the desired channel being trained (1,2 or 3).NOTE: Some gate operators and garage door openers require you to replace this Reprogramming Step 3 with procedures noted in the Gate Operator/Canadian Programming section. - Once "CHANNEL X TRAINED" is displayed on the EVIC, release both buttons. Programming is now complete. When the HomeLink(R) transceiver button is subsequently pressed, "CHANNEL X TRANSMIT" is displayed on the EVIC and your device should be activated, (garage door should open).NOTE: If the EVIC display shows "CHANNEL X TRANSMIT" (where X is channel 1,2 or 3) but your device does not activate, the device may be equipped with a rolling code system. Continue with the following steps 5 through 7 to complete the programming of a rolling code equipped device (most commonly a garage door opener manufactured after 1995). The assistance of a second person may make the following programming steps quicker and easier. - At the garage door opener receiver (motor head unit) in the garage, locate the "learn" or "smart" button. This can usually be found where the hanging antenna wire is attached to the motor head unit. - Firmly press and release the "learn" or "smart" button. (The name and color of the button may vary by manufacturer.)NOTE: There are 30 seconds in which to initiate step 7. - Return to the vehicle and firmly press and hold for two seconds, then release the reprogrammed HomeLink(R) transceiver button. Repeat the "press/hold/release" sequence a second time, and, depending on the brand of the garage door opener (or other rolling code equipped device), repeat this sequence a third time to complete the reprogramming. The HomeLink(R) transceiver should now activate your rolling code equipped device. Canadian Programming/Gate Programming Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 8160 Canadian radio frequencies require transmitter signals to "time-out" (or quit) after several seconds of transmission which may not be long enough for the HomeLink(R) transceiver to pick up the signal during programming. Similar to this Canadian law, some U.S. gate operators are designed to "time-out" in the same manner. If you live in Canada or you are having difficulties programming a gate operator by using the "Programming" procedures (regardless of where you live), replace programming common homeLink(R) transceiver codes step 3 with the following: NOTE: When programming a garage door opener or gate operator, it is advised to unplug the device or move the vehicle out of range during the "cycling" process to prevent possible overheating. - 3. Continue to press and hold the HomeLink(R) transceiver button while you press and release every two seconds ("cycle") your hand held transmitter until the frequency signal has successfully been accepted. The EVIC will display "CHANNEL X TRAINING" and then "CHANNEL X TRAINED". Proceed with "Programming" step 4 to complete. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way Memory Positioning Module: Diagrams Memory Seat Module C1 (Left Seat) 14 Way Connector C1 - (LEFT SEAT) 14 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 8167 Memory Positioning Module: Diagrams Memory Seat Module C2 (Left Seat) 6 Way Connector C2 - (LEFT SEAT) 6 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 8168 Memory Positioning Module: Diagrams Memory Seat Module C3 (Left Seat) 14 Way Connector C3 - (LEFT SEAT) 14 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 8169 Memory Positioning Module: Diagrams Memory Seat Module C4 (Left Seat) 6 Way Connector C4 - (LEFT SEAT) 6 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 8170 Memory Positioning Module: Diagrams Memory Seat Module C5 (Adjustable Pedals) 6 Way Connector C5 (ADJUSTABLE PEDALS) - 6 WAY MODULE-SEAT MEMORY (ADJUSTABLE PEDALS) - 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Description and Operation > Memory Seat Module - Description Memory Positioning Module: Description and Operation Memory Seat Module - Description DESCRIPTION NOTE: The scan tool standardization process must be performed on the Memory Seat Module (MSM) any time a new module is installed or the existing module is reflashed. The Memory Seat Module (MSM) is located underneath the driver seat, towards the front and on the outboard side. It is used in conjunction with the other modules in the memory system See: Memory Seat Module - Operation to recall the seat to one of two preset seat functional adjustments (horizontal, vertical, and recliner). The switch for the memory seat programming and selection mounts on the driver door trim panel. The MSM also controls the adjustable pedals, both for the memory and manual functionality. The adjustable accelerator and brake pedals are available on SLT and Limited models. On Limited, their positioning can be stored for recall by the memory system, allowing for two drivers to have unique, pre-programmed settings. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Description and Operation > Memory Seat Module - Description > Page 8173 Memory Positioning Module: Description and Operation Memory Seat Module - Operation OPERATION POWER/MEMORY SEAT The memory seat module receives input from the 8-way power seat switch, the driver seat position sensors, adjustable pedal control circuits (switch, sensor, and motor), and the data bus circuit. The memory switch, is wired to the memory mirror module which sends the message over the data bus. The memory seat module performs the following functions: - Positions the driver seat (vertical, horizontal, and recliner positions) and adjustable pedals. - Sends the memory save or recall (#1 or #2) command over the data bus circuit to the memory mirror modules, HVAC, and radio. - Provides for "linking" the key FOBs to memory. - Provides for the easy entry/exit feature. - Provides the tilt mirrors in reverse feature When a memory button is pressed (#1 or #2) on the memory switch, the driver door memory mirror module sends a recall message to the memory seat module (MSM). Then the MSM will position the driver seat and adjustable pedals to its preprogrammed location/setting. When the Remote Keyless Entry (RKE) Transmitter button is pressed, depending on which transmitter (#1 or #2), the SKREEM (RKE Receiver) sends the recall request and FOB number (#1 or #2) data message. This RKE transmitter function depends on if the MSM is programmed to trigger the recall (linked FOBs). A memory setting is saved by pressing the "set" button, then pressing either the memory "1" or "2" button within 5 seconds of pressing the "set" button. A memory setting is recalled by pressing either the memory "1" or "2" button, or by pressing the unlock button on a "linked" Remote Keyless Entry (RKE) transmitter. For driver safety, memorized settings can not be recalled if the transmission is in any position other than park or the seat belt is latched. A key FOB is "linked" to a memory setting by pressing the "set" button and then pressing either the memory "1" or "2" button within 5 seconds of pressing the set button, then by pressing the "lock" button on the selected key FOB. The memory system "Easy Entry and /Exit" feature provides the driver with more room to enter or exit the vehicle. The Easy Entry and Exit feature is disabled when the vehicle leaves the factory. An authorized dealer can enable this feature. When the seat is in a memorized position, it will move rearward 55 millimeters or to the end of its travel, whichever occurs first, when the key is removed from the ignition switch lock cylinder. The seat will return to the memory position when the driver turns the vehicle's ignition switch out of the LOCK position. The memory system "learns" the seat and adjustable pedal motor maximum end positions when the motor reaches the limit of travel in any direction and stalls. Subsequently, movement will stop just short of that position to avoid extra stress on the motors and mechanisms. If the system learned a maximum position as a result of an obstruction, as for instance if a large object was placed on the floor behind the seat, the system can relearn the "true" maximum position through manually operating the power seat after the obstruction is removed. NOTE: It is normal for the power accessories contained in the memory system to stop at the maximum "learned" position and then continue to the "true" maximum position when the control switch is released and then applied in the same direction a second time. Certain functions and features of the memory system rely upon resources shared with other electronic modules in the vehicle over the Controller Area Network (CAN) bus. The CAN bus allows the sharing of sensor information. This helps to reduce wire harness complexity, internal controller hardware, and component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. For diagnosis of these electronic modules or of the CAN bus, the use of a scan tool and the proper diagnostic information are needed. The tilt mirrors in reverse feature provides for tilting the sideview (outside) mirrors down a predetermined angle, providing a better view of the ground next to the rear portion of the vehicle. The tilt mirrors in reverse feature is disabled when the vehicle leaves the factory. An authorized dealer can enable this feature. Operation of the tilt mirrors is as follows: - Sideview mirrors will tilt down when the vehicle transmission is shifted into Reverse. - Sideview mirrors will return to the original position when the vehicle transmission is shifted out of Reverse. ADJUSTABLE PEDALS The pedals swing on a large arc, the radius and angle of which were selected on the basis of ergonomic studies, that puts them in the proper position for use by the smaller driver - higher and angled upward as well as rearward. Powered by the small electric motor driving a gear train at each pedal, adjustment is precise, quiet, and smooth throughout the range. A paddle-type switch on the instrument panel to the left of the steering column actuates the electric motor-driven mechanism through the memory seat module (MSM). Pushing up the paddle brings the pedals closer and vice versa. Movement Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Description and Operation > Memory Seat Module - Description > Page 8174 stops when the switch is released. MSM logic prevents pedal adjustment when the automatic speed control (cruise control) is set (controlling speed), and when the transmission is in reverse. This feature protects against a loss of reference position when neither foot is on the pedal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Description and Operation > Page 8175 Memory Positioning Module: Testing and Inspection MEMORY SEAT MODULE Any diagnosis of the memory seat system/module should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Module - Removal Memory Positioning Module: Service and Repair Memory Seat Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver seat cushion/cover (2) See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 3. Unsnap the memory seat module (4) from the side brackets. 4. Pivot the module upward and disconnect the electrical connectors (1). 5. Pull the module rearward to remove it from the front of the seat frame (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Module - Removal > Page 8178 Memory Positioning Module: Service and Repair Memory Seat Module - Installation INSTALLATION 1. Place the module (4) into position making sure the front snaps into the seat frame (3). 2. Connect the memory seat module harness connectors (1). 3. Pivot the module (4) downward and snap it into place in the side brackets. 4. Install the driver seat cushion/cover (2) See: Body and Frame/Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Installation. 5. Connect the battery negative cable. 6. Using an appropriate scan tool go to the MSM miscellaneous functions and perform the standardization routine. 7. Verify system and vehicle operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 8182 Seat Memory Switch: Diagrams Connector - (LEFT FRONT DOOR) 6 WAY SWITCH-MEMORY SELECTOR - (LEFT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 8187 Pedal Positioning Motor: Diagrams Connector - (INSTRUMENT PANEL) 6 WAY MOTOR-ADJUSTABLE PEDALS - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Locations > Page 8188 Pedal Positioning Motor: Description and Operation DESCRIPTION NOTE: The Adjustable Pedal Assembly can be serviced in four sub-components, Brake Pedal Assy, Accelerator Pedal Assy including the Accelerator Pedal and drive motor, (3) Drive Cable between the two pedals, (1) Bracket housing (2). NOTE: When replacing the components both pedal assemblies must be in the fully down position toward the floor for proper adjustment, Pedals can be moved manually by rotating the cable on the component not being replaced. New components come in the correct position until activated. The Adjustable Pedals System (APS) is designed to enable the fore and aft repositioning of the brake and accelerator pedals. This results in improved ergonomics in relation to the steering wheel for taller and shorter drivers. Being able to adjust the pedal positions also allows the driver to set steering wheel tilt and seat position to the most comfortable position. The position of the brake and accelerator pedals can be adjusted without compromising safety or comfort in actuating the pedals. Change of pedal position is accomplished by means of a motor driven screw. Operating the adjustable pedal switch activates the pedal drive motor located on the accelerator pedal assembly. The pedal drive motor turns a screw that changes the position of the brake and accelerator pedals simultaneously through a drive motor. The pedal can be moved rearward (closer to the driver) or forward (away from driver). The accelerator pedal is moved by way of the drive cable to a position where the driver feels most comfortable. The accelerator pedal is moved at the same time and the same distance as the brake pedal. Neither the pedal drive motor nor drive mechanism are subject to the mechanical stress of brake or accelerator application. - SYSTEM FEATURES: - Range of Adjustment: The pedals may be adjusted up to 3 in. (75 mm) - Pedal Adjustment Speed: 0.5 in./sec (12.5 mm/sec) - Pedal Adjustment Inhibitors: Pedal adjustment is inhibited when the vehicle is in reverse or when cruise control is activated. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Service and Repair > Removal Pedal Positioning Motor: Service and Repair Removal REMOVAL The Adjustable Pedal Motor is not serviced separately, It is serviced as an assembly within the Accelerator Pedal Sub-Assembly. To remove the brake pedal slide: 1. Remove the C-clip from the pin. 2. Remove the pin from the pedal bracket. 3. Disconnect the electrical wiring connector from the motor. NOTE: When replacing the components both pedal assemblies must be in the fully down position toward the floor for proper adjustment, Pedals can be moved manually by rotating the cable on the component not being replaced. New components come in the correct position until activated. 4. Remove the cable by squeezing the tabs together to remove from the motor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Motor > Component Information > Service and Repair > Removal > Page 8191 Pedal Positioning Motor: Service and Repair Installation INSTALLATION NOTE: When replacing the components both pedal assemblies must be in the fully down position toward the floor for proper adjustment, Pedals can be moved manually by rotating the cable on the component not being replaced. New components come in the correct position until activated. 1. Install the cable by squeezing the tabs together and sliding it over the motor then release. 2. Reconnect the electrical wiring connector to the motor. 3. Install the pin to the pedal bracket. 4. Install the C-clip to the pin. 5. Check for proper operation of the pedal assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Relay > Component Information > Locations Pedal Positioning Relay: Locations Adjustable Pedals Relay is located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Relay > Component Information > Locations > Page 8195 Pedal Positioning Relay: Diagrams Connector (IN IPM) RELAY-ADJUSTABLE PEDALS (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Sensor > Component Information > Locations > Page 8199 Pedal Positioning Sensor: Diagrams Connector - (INSTRUMENT PANEL) 3 WAY SENSOR-ADJUSTABLE PEDALS - (INSTRUMENT PANEL) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Locations > Page 8203 Pedal Positioning Switch: Diagrams Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-ADJUSTABLE PEDALS - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Service and Repair > Removal Pedal Positioning Switch: Service and Repair Removal REMOVAL 1. Remove the lower drivers side bezel. 2. Disconnect the electrical connector (2) from the adjustable pedal switch (1). 3. Remove the switch from the lower drivers side bezel by squeezing the retaining clips together and pushing the switch outwards Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Pedal Positioning System > Pedal Positioning Switch > Component Information > Service and Repair > Removal > Page 8206 Pedal Positioning Switch: Service and Repair Installation INSTALLATION 1. Install the switch (1) to the lower drivers side bezel by pushing the switch inwards seating the retaining clips to the lower drivers side bezel. 2. Reconnect the electrical connector (2) to the adjustable pedal switch (1). 3. Install the lower drivers side bezel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations Amplifier: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations > Page 8211 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Radio Amplifier C1 (Body) 20 Way Amplifier: Diagrams Radio Amplifier C1 (Body) 20 Way Connector C1 - (BODY) 20 WAY AMPLIFIER-RADIO - (BODY) 20 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Radio Amplifier C1 (Body) 20 Way > Page 8214 Amplifier: Diagrams Radio Amplifier C2 (Instrument Panel) 14 Way Connector C2 - (INSTRUMENT PANEL) 14 WAY AMPLIFIER-RADIO - (INSTRUMENT PANEL) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Amplifier - Description Amplifier: Description and Operation Amplifier - Description DESCRIPTION The amplifier can have one of two ratings: 288 watt (RD7), or 384 watt (RD6). The amplifier is mounted to the right cowl side panel under the passenger side of the instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Description and Operation > Amplifier - Description > Page 8217 Amplifier: Description and Operation Amplifier - Operation OPERATION The amplifier receives fused battery current from a fuse in the Junction Block (JB) at all times. The internal circuitry of the amplifier switches the amplifier on based upon a CAN bus message that is received from the radio receiver whenever the radio is turned on. The amplifier receives the sound signal inputs from the left and right rear outputs of the radio, then sends the amplified speaker outputs for each of those channels to the speakers. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Amplifier - Removal Amplifier: Service and Repair Amplifier - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the right side cowl trim. 3. Remove mounting fasteners. 4. Disconnect electrical harness connectors and remove amplifier. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Service and Repair > Amplifier - Removal > Page 8220 Amplifier: Service and Repair Amplifier - Installation INSTALLATION 1. Connect wire harness connectors to amplifier. Position amplifier into place. 2. Install and tighten mounting fasteners. 3. Install right side cowl trim cover. 4. Connect battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Description and Operation > Radio Noise Suppression - Description Radio/Stereo Noise Filter: Description and Operation Radio Noise Suppression - Description DESCRIPTION Radio noise suppression devices are installed on this vehicle. Radio Frequency Interference (RFI) and ElectroMagnetic Interference (EMI) can be produced by any on-board or external source of electromagnetic energy. These electromagnetic energy sources can radiate electromagnetic signals through the air, or conduct them through the vehicle electrical system. When the audio system converts RFI or EMI to an audible acoustic wave form, it is referred to as radio noise. This undesirable radio noise is generally manifested in the form of "buzzing," "hissing," "popping," "clicking," "crackling," and/or "whirring" sounds. In most cases, RFI and EMI radio noise can be suppressed using a combination of vehicle and component grounding, filtering and shielding techniques. This vehicle is equipped with radio noise suppression devices that were designed to minimize exposure to typical sources of RFI and EMI; thereby, minimizing radio noise complaints. Radio noise suppression is accomplished primarily through circuitry or devices that are integral to the radios, audio power amplifiers and other on-board electrical components such as generators, wiper motors, blower motors, and fuel pumps that have been found to be potential sources of RFI or EMI. External radio noise suppression devices that are used on this vehicle to control RFI or EMI, and can be serviced, include the following: - Engine-to-frame ground strap - This length of braided ground strap has an eyelet terminal connector crimped to each end. One end is secured to the engine cylinder heads. The other is secured to the frame. - Resistor-type spark plugs - This type of spark plug has an internal resistor connected in series between the spark plug terminal and the center electrode to help reduce the production of electromagnetic radiation that can result in radio noise. - Exhaust-to-frame ground strap - This length of braided ground strap has an eyelet terminal connector crimped to each end. One end is secured to the exhaust pipe. The other is secured to the frame. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Description and Operation > Radio Noise Suppression - Description > Page 8226 Radio/Stereo Noise Filter: Description and Operation Radio Noise Suppression - Operation OPERATION There are two common strategies that can be used to suppress Radio Frequency Interference (RFI) and Electro Magnetic Interference (EMI) radio noise. The first suppression strategy involves preventing the production of RFI and EMI electromagnetic signals at their sources. The second suppression strategy involves preventing the reception of RFI and EMI electromagnetic signals by the audio system components. The use of braided ground straps in key locations is part of the RFI and EMI prevention strategy. These ground straps ensure adequate ground paths, particularly for high current components such as many of those found in the starting, charging, ignition, engine control and transmission control systems. An insufficient ground path for any of these high current components may result in radio noise caused by induced voltages created as the high current seeks alternative ground paths through components or circuits intended for use by, or in close proximity to the audio system components or circuits. Preventing the reception of RFI and EMI is accomplished by ensuring that the audio system components are correctly installed in the vehicle. Loose, corroded or improperly soldered wire harness connections, improperly routed wiring and inadequate audio system component grounding can all contribute to the reception of RFI and EMI. A properly grounded antenna body and radio chassis, as well as a shielded antenna coaxial cable with clean and tight connections will each help reduce the potential for reception of RFI and EMI. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Radio Noise Suppression - Removal Radio/Stereo Noise Filter: Service and Repair Radio Noise Suppression - Removal REMOVAL ENGINE TO FRAME 1. Disconnect and isolate the battery negative cable. 2. Remove the mounting fasteners from the engine cylinder heads. 3. Remove mounting fastener from frame and remove strap. EXHAUST TO FRAME GROUND STRAP Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Radio Noise Suppression - Removal > Page 8229 1. Disconnect and isolate the battery negative cable. 2. Remove mounting fastener from exhaust pipe. 3. Remove mounting fastener from frame and remove ground strap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Radio Noise Suppression - Removal > Page 8230 Radio/Stereo Noise Filter: Service and Repair Radio Noise Suppression - Installation INSTALLATION ENGINE TO BODY 1. Position ground strap to engine and install mounting fasteners. 2. Tighten mounting fasteners. 3. Position ground strap and install mounting fastener. 4. Tighten mounting fastener. EXHAUST TO FRAME GROUND STRAP Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Service and Repair > Radio Noise Suppression - Removal > Page 8231 1. Position ground strap to exhaust pipe and install mounting fastener. 2. Tighten mounting fastener. 3. Position ground strap to frame and install mounting fastener. 4. Tighten mounting fastener. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch > Page 8236 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way Remote Switch: Diagrams Left Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-LEFT - (STEERING WHEEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way > Page 8239 Remote Switch: Diagrams Right Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-RIGHT - (STEERING WHEEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Remote Radio Switches Description Remote Switch: Description and Operation Remote Radio Switches - Description DESCRIPTION Two rocker-type switches are mounted in the sides of the rear (instrument panel side) steering wheel trim cover. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player or CD player. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Remote Radio Switches Description > Page 8242 Remote Switch: Description and Operation Remote Radio Switches - Operation OPERATION The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Instrument cluster through the clockspring. The instrument cluster sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the instrument cluster senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Controller Area Network (CAN) data bus to the radio. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 8243 Remote Switch: Testing and Inspection REMOTE RADIO SWITCHES Any diagnosis of the audio system should begin with the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Remove the remote radio switch(es) (1) and (2) from the steering wheel See: Service and Repair/Remote Radio Switches - Removal. 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test table. If the remote radio switch resistances are not as indicated, replace the inoperative switch. REMOTE RADIO SWITCH TEST Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal Remote Switch: Service and Repair Remote Radio Switches - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag (5) from the steering wheel (1). See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag - Removal. 3. Remove the speed control switch (3) or (6) located on the same side of the steering wheel as the remote radio switch that is being serviced. See: Cruise Control/Cruise Control Switch/Service and Repair/Speed Control Switch - Removal. 4. Disconnect the steering wheel wire harness connector from the connector receptacle of the remote radio switch. 5. Disengage the four remote radio switch latches that secure the switch to the inside of the mounting hole in the steering wheel rear trim cover. 6. From the outside of the steering wheel rear trim cover, remove the remote radio switch (2) from the trim cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches - Removal > Page 8246 Remote Switch: Service and Repair Remote Radio Switches - Installation INSTALLATION 1. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch latches is fully engaged in the mounting hole of the steering wheel rear trim cover. 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch. 4. Install the speed control switch onto the steering wheel. See: Cruise Control/Cruise Control Switch/Service and Repair/Speed Control Switch Installation. 5. Install the driver side airbag to the steering wheel. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag - Installation. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Front Door Speaker Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Front Door Speaker > Page 8251 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Front Door Speaker > Page 8252 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Front Door Speaker > Page 8253 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Front Door Speaker > Page 8254 Speaker: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Front Door Speaker > Page 8255 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Front Door Speaker > Page 8256 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Front Door Speaker > Page 8257 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Front Door Speaker > Page 8258 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Front Door Speaker > Page 8259 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Front Door Speaker > Page 8260 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Front Door Speaker > Page 8261 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Locations > Left Front Door Speaker > Page 8262 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Rear Door Speaker (Left Rear Door) 3 Way Speaker: Diagrams Left Rear Door Speaker (Left Rear Door) 3 Way Connector - (LEFT REAR DOOR) 3 WAY SPEAKER-LEFT REAR DOOR - (LEFT REAR DOOR) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Rear Door Speaker (Left Rear Door) 3 Way > Page 8265 Speaker: Diagrams Left Front Door Speaker (Left Front Door) 3 Way Connector - (LEFT FRONT DOOR) 3 WAY SPEAKER-LEFT FRONT DOOR - (LEFT FRONT DOOR) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Rear Door Speaker (Left Rear Door) 3 Way > Page 8266 Speaker: Diagrams Right Front Door Speaker (Right Front Door) 3 Way Connector - (RIGHT FRONT DOOR) 3 WAY SPEAKER-RIGHT FRONT DOOR - (RIGHT FRONT DOOR) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Rear Door Speaker (Left Rear Door) 3 Way > Page 8267 Speaker: Diagrams Subwoofer Speaker (Premium) (Body) 4 Way Connector (PREMIUM) - (BODY) 4 WAY SPEAKER-SUBWOOFER (PREMIUM) - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Rear Door Speaker (Left Rear Door) 3 Way > Page 8268 Speaker: Diagrams Left Rear Door Speaker (Left Rear Door) 3 Way Connector - (LEFT REAR DOOR) 3 WAY SPEAKER-LEFT REAR DOOR - (LEFT REAR DOOR) 3 WAY Left Front Door Speaker (Left Front Door) 3 Way Connector - (LEFT FRONT DOOR) 3 WAY SPEAKER-LEFT FRONT DOOR - (LEFT FRONT DOOR) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Rear Door Speaker (Left Rear Door) 3 Way > Page 8269 Right Front Door Speaker (Right Front Door) 3 Way Connector - (RIGHT FRONT DOOR) 3 WAY SPEAKER-RIGHT FRONT DOOR - (RIGHT FRONT DOOR) 3 WAY Subwoofer Speaker (Premium) (Body) 4 Way Connector (PREMIUM) - (BODY) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Rear Door Speaker (Left Rear Door) 3 Way > Page 8270 SPEAKER-SUBWOOFER (PREMIUM) - (BODY) 4 WAY Right Rear Door Speaker (Right Rear Door) 3 Way Connector - (RIGHT REAR DOOR) 3 WAY SPEAKER-RIGHT REAR DOOR - (RIGHT REAR DOOR) 3 WAY Left Front Tweeter Speaker (Premium) (Instrument Panel) 2 Way Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Rear Door Speaker (Left Rear Door) 3 Way > Page 8271 Connector (PREMIUM) - (INSTRUMENT PANEL) 2 WAY SPEAKER-TWEETER-LEFT FRONT (PREMIUM) - (INSTRUMENT PANEL) 2 WAY Left Rear Tweeter Speaker (Premium) (Left Rear Door) 3 Way Connector (PREMIUM) - (LEFT REAR DOOR) 3 WAY SPEAKER-TWEETER-LEFT REAR (PREMIUM) - (LEFT REAR DOOR) 3 WAY Right Front Tweeter Speaker (Premium) (Instrument Panel) 2 Way Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Left Rear Door Speaker (Left Rear Door) 3 Way > Page 8272 Connector (PREMIUM) - (INSTRUMENT PANEL) 2 WAY SPEAKER-TWEETER-RIGHT FRONT (PREMIUM) - (INSTRUMENT PANEL) 2 WAY Right Rear Tweeter Speaker (Premium) (Right Rear Door) 3 Way Connector (PREMIUM) - (RIGHT REAR DOOR) 3 WAY SPEAKER-TWEETER-RIGHT REAR (PREMIUM) - (RIGHT REAR DOOR) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 8273 Speaker: Description and Operation DESCRIPTION STANDARD The standard equipment speaker system includes speakers in four locations. One 16.5 centimeter (6.5 inch) diameter speaker is located in each front door. There is also one 16.5 centimeter (6.5 inch) diameter speaker located in each rear door. MIDLEVEL The midlevel speaker system features eight speakers in eight locations. One 16.5 centimeter (6.5 inch) diameter speaker is located in each front door. There is also one 16.5 centimeter (6.5 inch) diameter speaker located in each rear door. A 1.9 centimeter tweeter is mounted high in each rear door trim panel. Two tweeters (8.9 centimeter (3.5 inch)) are also located on the top portion of the instrument panel. The midlevel speaker system includes an amplifier. The total available power of the premium speaker system is 288 watts. PREMIUM The premium speaker system features nine speakers in nine locations. One 16.5 centimeter (6.5 inch) diameter speaker is located in each front door. There is also one 16.5 centimeter (6.5 inch) diameter speaker located in each rear door. A 1.9 centimeter tweeter is mounted high in each rear door trim panel. Two tweeters (8.9 centimeter (3.5 inch)) are also located on the top portion of the instrument panel. Included with the premium speaker package is a subwoofer located in the left rear quarter panel. The premium speaker system also includes an amplifier. The total available power of the premium speaker system is 384 watts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 8274 Speaker: Testing and Inspection SPEAKER Any diagnosis of the Audio system should begin with the use of a scan tool and the appropriate Diagnostic Service information. Refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. CAUTION: The speaker output of the radio is a "floating ground" system. Do not allow any speaker lead to short to ground, as damage to the radio may result. 1. If all speakers are inoperative, check the radio fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 2. Check the amplifier fuse (if equipped) in the junction block. If OK, go to Step 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the ON position. Turn the radio receiver ON. Adjust the balance and fader control controls to check the performance of each individual speaker. Note the speaker locations that are not performing correctly. Go to Step 4. 4. Turn the radio OFF. Turn the ignition OFF. Disconnect and isolate the battery negative cable. If vehicle is not equipped with a amplifier, remove the radio receiver. If the vehicle is equipped with an amplifier, disconnect the wire harness connectors. There are two connectors. The one on the body harness has body speakers only. The other on the instrument panel harness has the instrument panel speakers, battery, ground, and CAN. Go to Step 5. 5. Check both the speaker feed (+) circuit and return (-) circuit cavities for the inoperative speaker at the wire harness connector for continuity to ground. There should be no continuity. If OK, go to Step 6. If not OK, repair the shorted speaker feed (+) and/or return (-) circuits(s) to the speaker as required. 6. Disconnect wire harness connector at the inoperative speaker. Check for continuity between the speaker feed (+) circuit cavities of the radio receiver wire harness connector or if equipped, the amplifier wire harness connector and the speaker wire harness connector. Repeat the check between the speaker return (-) circuit cavities of the radio receiver wire harness connector and the speaker wire harness connector. In each case, there should be continuity. If OK, replace the faulty speaker. If not OK, repair the open speaker feed (+) and/or return (-) circuits(s) as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Removal Speaker: Service and Repair Speaker - Removal REMOVAL FRONT DOOR 1. Disconnect and isolate the battery negative cable. 2. Remove the front door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Removal. 3. Remove the mounting fasteners. 4. Remove speaker and disconnect the electrical harness connector. INSTRUMENT PANEL 1. Disconnect and isolate the battery negative cable. 2. Remove instrument panel defroster grille See: Heating and Air Conditioning/Air Register/Service and Repair/Defroster Grille - Removal. 3. Remove the mounting fasteners. 4. Remove speaker and disconnect the electrical harness connector. REAR DOOR Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Removal > Page 8277 1. Disconnect and isolate the battery negative cable. 2. Remove the rear door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Removal. 3. Remove the mounting fasteners. 4. Remove speaker and disconnect the electrical harness connector. REAR DOOR TWEETER 1. Disconnect and isolate the battery negative cable. 2. Remove the rear door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Removal. 3. Disconnect the electrical harness connector (1) and remove tweeter (2). SUBWOOFER 1. Disconnect and isolate the battery negative cable. 2. Remove the quarter panel trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Remove the mounting fasteners. 4. Remove speaker and disconnect the electrical harness connectors. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Removal > Page 8278 Speaker: Service and Repair Speaker - Installation INSTALLATION FRONT DOOR 1. Connect electrical harness connector and position speaker to door. 2. Install and tighten mounting fasteners. 3. Install door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel - Installation. 4. Connect battery negative cable. INSTRUMENT PANEL 1. Connect electrical harness connector and position speaker to instrument panel. 2. Install and tighten mounting fasteners. 3. Install instrument panel top cover. 4. Connect battery negative cable. REAR DOOR Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Removal > Page 8279 1. Connect electrical harness connector and position speaker to door. 2. Install and tighten mounting fasteners. 3. Install door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Installation. 4. Connect battery negative cable. REAR DOOR TWEETER 1. Connect electrical harness connector and position speaker to door trim panel. 2. Install and tighten mounting fasteners. 3. Install door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Installation. 4. Connect battery negative cable. SUBWOOFER 1. Connect electrical harness connector and position speaker. 2. Install and tighten mounting fasteners. 3. Install quarter panel trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker - Removal > Page 8280 4. Connect battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Accessory Delay Relay is located in the Junction Block (JB). Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 8286 Accessory Delay Relay: Diagrams Connector (IN JB) RELAY-ACCESSORY DELAY (IN JB) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Sentry Key Immobilizer Module (SKREEM) - Description Alarm Module: Description and Operation Sentry Key Immobilizer Module (SKREEM) - Description DESCRIPTION The Sentry Key REmote Entry Module (SKREEM) (1) is sometimes referred to as the Wireless Control Module (WCM), and is also known as the Sentry Key Immobilizer Module (SKIM). The SKREEM is the primary component of the Sentry Key Immobilizer System (SKIS). It is also the receiver for the Remote Keyless Entry (RKE) system. The SKREEM is located on the right side of the steering column, near the ignition lock cylinder housing and is concealed beneath the steering column shrouds. The molded black plastic housing for the SKREEM has an integral molded plastic halo-like antenna ring (4) that extends from the bottom. When the SKREEM is properly installed on the steering column, the antenna ring is oriented around the circumference of the ignition lock cylinder housing. A single integral connector receptacle (3) is located just behind the antenna ring on the bottom of the SKREEM housing. An integral molded plastic mounting tab (2) on the rear corner of the SKREEM housing has a hole in the center through which a screw passes to secure the unit to the steering column. The SKREEM is connected to the vehicle electrical system through a single take out and connector of the instrument panel wire harness. Several unique SKREEM modules are used: one for vehicles equipped with RKE only, one for vehicles equipped with RKE and SKIS, and another version has an additional coaxial connector receptacle that allows it to receive inputs from the optional remote start antenna module. The SKREEM cannot be adjusted or repaired. If ineffective or damaged, the entire SKREEM unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Description and Operation > Sentry Key Immobilizer Module (SKREEM) - Description > Page 8291 Alarm Module: Description and Operation Sentry Key Immobilizer Module (SKREEM) - Operation OPERATION The Sentry Key REmote Entry Module (SKREEM) (also known as the Sentry Key Immobilizer Module/SKIM or the Wireless Control Module/WCM) contains a Radio Frequency (RF) transceiver and a microprocessor. The SKREEM transmits RF signals to, and receives RF signals from the Sentry Key transponder through a tuned antenna enclosed within the molded plastic antenna ring integral to the SKREEM housing. If this antenna ring is not mounted properly around the ignition lock cylinder housing, communication problems between the SKREEM and the transponder may arise. These communication problems will result in Sentry Key transponder-related faults. The SKREEM also serves as the Remote Keyless Entry (RKE) RF receiver and may receive RF inputs either directly through an internal antenna from the RKE key fob transmitter or, on vehicles equipped with an optional remote start system, indirectly through the external remote start antenna module. See: Body and Frame/Locks/Power Locks/Description and Operation/Power Locks Description. The SKREEM communicates over the Controller Area Network (CAN) data bus with the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN), the Powertrain Control Module (PCM), or the diagnostic scan tool. The SKREEM and the PCM both use software that includes a rolling code algorithm strategy, which helps to reduce the possibility of unauthorized Sentry Key Immobilizer System (SKIS) disarming. The rolling code algorithm ensures security by preventing an override of the SKIS through the unauthorized substitution of the SKREEM or the PCM. However, the use of this strategy also means that replacement of either the SKREEM or the PCM units will require a system initialization procedure to restore system operation. The SKREEM retains in memory the ID numbers of any Sentry Key transponder that is programmed into it. A maximum of eight Sentry Key transponders can be programmed into the SKREEM. For added system security, each SKREEM is programmed with a unique Secret Key code. This code is stored in memory, sent over the CAN data bus to the PCM, and is encoded to the transponder of every Sentry Key that is programmed into the SKREEM. Therefore, the Secret Key code is a common element that is found in every component of the SKIS. Another security code, called a PIN, is used to gain access to the SKREEM Secured Access Mode. The Secured Access Mode is required during service to perform the SKIS initialization and Sentry Key transponder programming procedures. The SKREEM also stores the Vehicle Identification Number (VIN) in its memory, which it learns through a CAN data bus message from the PCM during SKIS initialization. In the event that a SKREEM replacement is required, the Secret Key code can be transferred to the new SKREEM from the PCM using the diagnostic scan tool and the SKIS initialization procedure. Proper completion of the SKIS initialization will allow the existing Sentry Keys to be programmed into the new SKREEM so that new keys will not be required. In the event that the original Secret Key code cannot be recovered, SKREEM replacement will also require new Sentry Keys. The diagnostic scan tool will alert the technician during the SKIS initialization procedure if new Sentry Keys are required. When the ignition switch is turned to the ON position, the SKREEM transmits an RF signal to excite the transponder in the ignition key. The SKREEM then waits for an RF signal response from the transponder. If the response received identifies the key as valid, the SKREEM sends an electronic valid key message to the PCM over the CAN data bus. If the response received identifies the key as invalid or if no response is received from the key transponder, the SKREEM sends an invalid key message to the PCM. The PCM will enable or disable engine operation based upon the status of the SKREEM messages. It is important to note that the default condition in the PCM is an invalid key; therefore, if no message is received from the SKREEM by the PCM, the engine will be disabled and the vehicle immobilized after two seconds of running. The SKREEM also sends electronic security indicator request messages to the EMIC over the CAN data bus to tell the EMIC how to operate the security indicator. The security indicator request message from the SKREEM tells the EMIC to turn the indicator ON for about three seconds each time the ignition switch is turned to the ON position as a bulb test. After completion of the bulb test, the SKREEM sends security indicator request messages to the EMIC to turn the indicator OFF, turn the indicator ON, or to flash the indicator ON and OFF. If the security indicator flashes or stays ON solid after the bulb test, it signifies a SKIS fault. If the SKREEM detects a system malfunction or if the SKIS has become ineffective, the security indicator will stay ON solid. If the SKREEM detects an invalid key or if a key transponder-related fault exists, the security indicator will flash. If the vehicle is equipped with the Customer Learn transponder programming feature, the SKREEM will also send messages to the EMIC to flash the security indicator whenever the Customer Learn programming mode is being utilized. See: Antitheft and Alarm Systems/Service and Repair. The SKIS performs a self-test each time the ignition switch is turned to the ON position, and will store fault information in the form of a Diagnostic Trouble Code (DTC) in SKREEM memory if a system malfunction is detected. The hard wired circuits of the SKREEM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the SKREEM or the electronic controls or communication between other modules and devices that provide some features of the SKIS. The most reliable, efficient, and accurate means to diagnose the SKREEM or the electronic controls and communication related to SKREEM operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal Alarm Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, push gently inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 8294 8. Disconnect the wire harness connector (2) from the Sentry Key REmote Entry Module (SKREEM) (1). 9. On vehicles equipped with the optional remote start system, disconnect the coaxial cable from the coaxial connector receptacle on the SKREEM. 10. Remove the screw (2) that secures the SKREEM (1) to the steering column housing. 11. Disengage the antenna ring (3) from around the ignition lock cylinder housing (4) and remove the SKREEM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 8295 Alarm Module: Service and Repair Sentry Key Immobilizer Module (SKREEM) - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the Sentry Key REmote Entry Module (SKREEM) (1) onto the steering column with the antenna ring (3) oriented around the ignition lock cylinder housing (4). 2. Install and tighten the screw (2) that secures the SKREEM to the steering column housing. Tighten the screw to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the SKREEM (1). 4. On vehicles equipped with the optional remote start system, reconnect the coaxial cable to the coaxial connector receptacle on the SKREEM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Sentry Key Immobilizer Module (SKREEM) - Removal > Page 8296 5. Position the lower shroud (3) onto the steering column (4). 6. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 7. Position the upper shroud (1) onto the steering column over the lower shroud. On vehicles equipped with an automatic transmission, be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 8. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 9. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). 10. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 11. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. NOTE: On vehicles equipped with the optional Sentry Key Immobilizer System (SKIS), if the Sentry Key REmote Entry Module (SKREEM) is replaced with a new unit, a diagnostic scan tool MUST be used to initialize the new SKREEM and to program at least two Sentry Key transponders before the vehicle can be operated. See: Antitheft and Alarm Systems/Service and Repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C1 (Headliner) 16 Way Entertainment System Control Module: Diagrams Satellite Video Module C1 (Headliner) 16 Way Connector C1 - (HEADLINER) 16 WAY MODULE-SATELLITE VIDEO - (HEADLINER) 16 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C1 (Headliner) 16 Way > Page 8301 Entertainment System Control Module: Diagrams Satellite Video Module C2 (Body Left) 2 Way Connector C2 - (BODY LEFT) 2 WAY MODULE-SATELLITE VIDEO - (BODY LEFT) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C1 (Headliner) 16 Way > Page 8302 Entertainment System Control Module: Diagrams Satellite Video Module C3 (Body Left) 2 Way Connector C3 - (BODY LEFT) 2 WAY MODULE-SATELLITE VIDEO - (BODY LEFT) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Diagrams > Satellite Video Module C1 (Headliner) 16 Way > Page 8303 Entertainment System Control Module: Diagrams Satellite Video Module C4 (Body) 2 Way Connector C4 - (BODY) 2 WAY MODULE-SATELLITE VIDEO - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Description and Operation > Satellite Video Module - Description Entertainment System Control Module: Description and Operation Satellite Video Module Description DESCRIPTION The satellite receiver module is located above the headliner near the rear liftgate opening. It is mounted to the roof panel with three mounting fasteners. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Description and Operation > Satellite Video Module - Description > Page 8306 Entertainment System Control Module: Description and Operation Satellite Video Module Operation OPERATION The satellite receiver module receives signals from the roof mounted antenna and processes this information before it is sent to the radio. The module operates on both battery feed circuits and CAN bus messages. It will operate with the ignition key in the run or accessory position only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Service and Repair > Satellite Video Module - Removal Entertainment System Control Module: Service and Repair Satellite Video Module - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Disconnect and isolate the battery negative cable. 2. Lower the headliner as necessary. 3. Remove the mounting bracket fasteners. 4. Disconnect the antenna and electrical harness connectors. 5. Remove the module from the mounting bracket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Entertainment System Control Module > Component Information > Service and Repair > Satellite Video Module - Removal > Page 8309 Entertainment System Control Module: Service and Repair Satellite Video Module - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. 1. Connect antenna and electrical harness connector to module. 2. Install module to mounting bracket. Tighten mounting fasteners. 3. Position module and bracket. Install new mounting fasteners. 4. Install headliner. 5. Connect battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 8313 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY MODULE-WIRELESS CONTROL - (INSTRUMENT PANEL) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 8314 Keyless Entry Module: Testing and Inspection SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations > Page 8315 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Park Assist Module C1 (Parktronics) 12 Way Parking Assist Control Module: Diagrams Park Assist Module C1 (Parktronics) 12 Way Connector C1 (PARKTRONICS) - 12 WAY MODULE-PARK ASSIST (PARKTRONICS) - 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Diagrams > Park Assist Module C1 (Parktronics) 12 Way > Page 8321 Parking Assist Control Module: Diagrams Park Assist Module C2 (Parktronics) 8 Way Connector C2 (PARKTRONICS) - 8 WAY MODULE-PARK ASSIST (PARKTRONICS) - 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Description and Operation > Park Assist Module Description Parking Assist Control Module: Description and Operation Park Assist Module - Description DESCRIPTION The Park Assist Module (3) is secured with three push-in plastic fasteners through three mounting tabs (2) integral to the module housing to the left inner quarter panel above the left rear wheel housing. The module is concealed beneath the quarter inner trim panel. Concealed within the molded plastic park assist module housing is a microprocessor and the other electronic circuitry of the module. The module housing is sealed to enclose and protect the internal electronic circuitry. The module software is flash programmable. Two connector receptacles (1) containing terminal pins are integral to the rearward-facing side of the housing. The module is connected to the vehicle electrical system through two dedicated take outs and connectors of the body wire harness. The park assist module cannot be adjusted or repaired and, if damaged or ineffective, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Description and Operation > Park Assist Module Description > Page 8324 Parking Assist Control Module: Description and Operation Park Assist Module - Operation OPERATION The microprocessor in the park assist module contains the park assist system logic circuits. The module uses On-Board Diagnostics (OBD) and can communicate with other electronic modules in the vehicle as well as with the diagnostic scan tool using the Controller Area Network (CAN) data bus. This method of communication is also used for park assist system diagnosis and testing through the 16-way data link connector located on the driver side lower edge of the instrument panel. The module provides voltage to the four park assist sensors located behind the rear bumper fascia and to the park assist display located in the headliner just forward of the liftgate opening header. The module then monitors return inputs from each of the sensors and the display on dedicated hard wired data communication circuits. The sensor inputs allow the module to determine when an obstacle is in the rear path of the vehicle and enables the module to calculate the relative location of the obstacle, and whether the distance to that obstacle is increasing or decreasing. Pre-programmed decision algorithms and calibrations allow the module microprocessor to determine the appropriate park assist system outputs based upon the inputs received from the park assist sensors and electronic messages received from other modules in the vehicle over the CAN data bus. When the programmed conditions are met the module sends electronic messages to the park assist displays over a dedicated serial bus to obtain the proper park assist system visual and audible outputs. The module also broadcasts electronic messages over the CAN data bus to enable the other electronic features of the park assist system. The park assist module microprocessor continuously monitors all of the park assist system electrical circuits and components to determine the system readiness. If the module detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) and sends the appropriate electronic messages to the instrument cluster over the CAN data bus to control operation of certain park assist system audible warnings and textual messages displayed in the Electronic Vehicle Information Center (EVIC). The park assist module receives battery current on a fused ignition switch output (run-start) circuit through a fuse in the Junction Block (JB). The module receives ground through a ground circuit and take out of the body wire harness. These connections allow the module to be operational whenever the ignition switch is in the START or ON positions. The hard wired circuits between components related to the park assist module may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the park assist module or the electronic controls or communication between modules and other devices that provide some features of the park assist system. The most reliable, efficient, and accurate means to diagnose the park assist module or the electronic controls and communication related to park assist module operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Service and Repair > Park Assist Module Removal Parking Assist Control Module: Service and Repair Park Assist Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the trim from the left quarter inner panel to access the park assist module (5), which is located behind the power liftgate module (3) to the rear of the C-pillar (2) and above the left rear wheel housing. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel Removal. 3. Disconnect the two body wire harness connectors (1) from the park assist module connector receptacles. 4. Remove the three plastic push-in fasteners (4) that secure the module to the left quarter inner panel. 5. Remove the module from the left quarter inner panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Parking Assist Control Module > Component Information > Service and Repair > Park Assist Module Removal > Page 8327 Parking Assist Control Module: Service and Repair Park Assist Module - Installation INSTALLATION 1. Position the park assist module (5) to the left quarter inner panel, behind the power liftgate module (3) to the rear of the C-pillar (2) and above the left rear wheel housing. 2. Secure the module to the left quarter inner panel using three plastic push-in fasteners (4). 3. Reconnect the two body wire harness connectors (1) to the module connector receptacles. 4. Reinstall the trim onto the left quarter inner panel. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation. 5. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Voice Activation Module > Component Information > Locations > Page 8331 Voice Activation Module: Diagrams Connector - (INSTRUMENT PANEL) 22 WAY MODULE-HANDS FREE - (INSTRUMENT PANEL) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Hood Ajar Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Hood Ajar Switch > Page 8337 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 8338 Hood Sensor/Switch (For Alarm): Diagrams Connector (HEV) - 2 WAY SWITCH-HOOD AJAR 2 (HEV) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in three different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic market vehicles equipped with either an optional remote starter system or the optional Hybrid Electric Vehicle (HEV) system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole. For the vehicle theft and remote start applications, the switch is secured within the stamped metal inner left fender mounting flange within the engine compartment. For the HEV applications, the switch is secured within the stamped metal inner right fender mounting flange within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system or HEV system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description > Page 8341 Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export market vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Front Control Module (FCM). The FCM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic market vehicles only - white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the FCM and the hood ajar switch sense input of the FCM. The FCM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. When the hood switch is closed (hood is open), the remote start feature is disabled. In the Hybrid Electric Vehicle (HEV) system application (white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between ground and the hood ajar switch sense input of the Powertrain Control Module (PCM). The PCM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. When the hood switch is closed (hood is open), the gasoline engine auto-start feature is disabled. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting hole, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the FCM or PCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export market vehicle theft, domestic market remote starter or the HEV systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Removal Striker STRIKER NOTE: Vehicles equipped with two hood ajar switches are also equipped with two strikers. NOTE: The hood ajar switch strikers are not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using hand pressure, slide the hood ajar switch striker (2) toward the large end of the keyed mounting hole (3) in the inner hood panel reinforcement (1) far enough to disengage it. 3. Remove the striker from the inner hood panel reinforcement and discard. Switch SWITCH NOTE: Some vehicles are equipped with two hood ajar switches. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 3. From the top of the left or right front fender inner shield, squeeze the two hood ajar switch latch tabs (1) together and pull the switch upward out of Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal > Page 8344 the mounting hole (2). 4. Pull the hood ajar switch up through the hole far enough to access and disconnect the wire harness connector (3) from the switch connector receptacle. 5. Remove the hood ajar switch from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal > Page 8345 Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Installation Striker STRIKER NOTE: Vehicles equipped with two hood ajar switches are also equipped with two strikers. NOTE: The hood ajar switch striker caps are not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) into the large end of the keyed mounting hole (3) in the inner hood panel reinforcement (1) over the hood ajar switch. 2. Using hand pressure, slide the striker upward into the small end of the mounting hole in the inner hood panel reinforcement until it is fully engaged. 3. Close and latch the hood. Switch SWITCH NOTE: Some vehicles are equipped with two hood ajar switches. 1. Position the hood ajar switch (1) near the mounting hole (2) in the left front fender inner shield. 2. Reconnect the wire harness connector (3) to the switch connector receptacle. 3. Insert the switch into the mounting hole until the integral switch latch tabs lock it into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch - Removal > Page 8346 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. 5. Close and latch the hood. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Park Assist Sensor 8 (Park Assist) (Fascia RPA Harness) 3 Way Parking Assist Distance Sensor: Diagrams Park Assist Sensor 8 (Park Assist) (Fascia RPA Harness) 3 Way Connector (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY SENSOR-PARK ASSIST 8 (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Park Assist Sensor 8 (Park Assist) (Fascia RPA Harness) 3 Way > Page 8352 Parking Assist Distance Sensor: Diagrams Park Assist Sensor 9 (Park Assist) (Fascia RPA Harness) 3 Way Connector (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY SENSOR-PARK ASSIST 9 (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Park Assist Sensor 8 (Park Assist) (Fascia RPA Harness) 3 Way > Page 8353 Parking Assist Distance Sensor: Diagrams Park Assist Sensor 10 (Park Assist) (Fascia RPA Harness) 3 Way Connector (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY SENSOR-PARK ASSIST 10 (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Diagrams > Park Assist Sensor 8 (Park Assist) (Fascia RPA Harness) 3 Way > Page 8354 Parking Assist Distance Sensor: Diagrams Park Assist Sensor 11 (Park Assist) (Fascia RPA Harness) 3 Way Connector (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY SENSOR-PARK ASSIST 11 (PARK ASSIST) - (FASCIA RPA HARNESS) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Description and Operation > Park Assist Sensor Description Parking Assist Distance Sensor: Description and Operation Park Assist Sensor - Description DESCRIPTION Vehicles equipped with the park assist system have four park assist sensors (1) installed on the rear bumper fascia. Only the membrane (3) of each sensor is visible through a hole in the outer vertical surface of the fascia. The remainder of each sensor including the sensor mounting bracket, the sensor spacer and the sensor wiring connection is concealed behind the fascia. A sensor wire harness behind the fascia connects the sensors to the vehicle electrical system. Each of the four sensors is identical in construction and is interchangeable. The electronic circuitry and a communication chip for each sensor is enclosed and protected within the molded black plastic sensor housing. The housing includes an integral connector receptacle (4) and two integral latch tabs (2). The sensor membrane extends from the surface of the sensor housing, and is finished to match or contrast with the outer surface of the fascia. The numbering system for the park assist sensors allows for up to twelve sensors on the vehicle, six front and six rear. The sensors are numbered in a clockwise manner starting at the left front bumper. The left front sensor (if equipped with front park assist) is the number 1 sensor. The numbering continues in a clockwise direction around the vehicle. Since this vehicle uses only four rear sensors, sensor numbers 7 and 12 are omitted, so the left rear sensor is the number 11 sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Description and Operation > Park Assist Sensor Description > Page 8357 A resilient O-ring spacer around the circumference of each of the four sensor membranes (2) isolates the membrane from the openings in the fascia (1). Each sensor is snapped into its own dedicated molded plastic mounting bracket. Each mounting bracket is heat-staked to the back side of the rear fascia. The park assist sensors cannot be adjusted or repaired. If ineffective or damaged they must be replaced. The sensors and the spacers are each available for individual service replacement. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Description and Operation > Park Assist Sensor Description > Page 8358 Parking Assist Distance Sensor: Description and Operation Park Assist Sensor - Operation OPERATION The park assist sensors are ultrasonic transceivers that are completely controlled by the park assist module. The sensors transmit and receive ultrasonic signals. The sensors each receive battery current and ground in parallel from the module, but are each connected to individual dedicated serial bus communication circuits to the module. Each sensor membrane is oscillated, then quieted by the module in a pulsing fashion. While the sensor membrane oscillates, it emits an ultrasonic signal. This signal will bounce or echo off of objects in the path of the vehicle. While quieted, each membrane receives the echoes of the ultrasonic signals it and the other sensors have transmitted. The sensors then communicate this echo data over the serial bus lines back to the module. The microprocessor in the module uses the intervals between the ultrasonic transmission and reception data from the sensors to calculate the distance to any obstacles identified by the ultrasonic echoes. The hard wired circuits between components related to the park assist sensors may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the park assist sensors or the electronic controls or communication between modules and other devices that provide some features of the park assist system. The most reliable, efficient, and accurate means to diagnose the park assist sensors or the electronic controls and communication related to park assist sensor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Park Assist Sensor Removal Parking Assist Distance Sensor: Service and Repair Park Assist Sensor - Removal REMOVAL NOTE: The park assist sensors (3) and the sensor spacers (O-rings) are each available for separate service replacement. The sensor brackets (5) are bonded to and integral to the back side of the rear bumper fascia (2). 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. NOTE: The two outboard rear park assist sensors can be accessed for service with the rear bumper fascia installed on the vehicle. 2. For the two inboard rear park assist sensors only, remove the bumper fascia from the rear of the vehicle. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Removal. 3. From the back of the fascia (2), disconnect the wire harness connector (4) from the park assist sensor (3) connector receptacle. 4. Carefully pry the sensor bracket (5) latch features (1) away from the top and bottom latch tabs of the sensor far enough to disengage the sensor from the bracket. 5. Disengage the O-ring spacer from around the circumference of the sensor membrane protrusion. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Parking Assist Distance Sensor > Component Information > Service and Repair > Park Assist Sensor Removal > Page 8361 Parking Assist Distance Sensor: Service and Repair Park Assist Sensor - Installation INSTALLATION NOTE: The park assist sensors (3) and the sensor spacers (O-rings) are each available for separate service replacement. The sensor brackets (5) are bonded to and integral to the back side of the rear bumper fascia (2). 1. Engage the O-ring spacer around the circumference of the sensor membrane protrusion. NOTE: Production and all service replacement O-ring spacers are tapered. The wide side (base) of the O-ring should be seated against the sensor housing and the narrow side should be oriented toward the outer surface of the sensor membrane and the rear fascia. 2. Align and insert the sensor (3) into the sensor bracket (5) on the back of the rear bumper fascia (2) until the bracket latch features (1) are fully engaged over the top and bottom latch tabs of the sensor. Be certain that the sensor membrane is flush with the outer surface of the fascia. NOTE: Be certain that each sensor membrane is properly centered in the openings of the rear fascia and that the O-ring spacers are not pinched. Improper centering or pinched O-rings can be detrimental to proper park assist sensor operation. 3. From the back of the fascia, reconnect the wire harness connector (4) to the sensor connector receptacle. 4. For the two inboard rear park assist sensors only, reinstall the bumper fascia onto the rear of the vehicle. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Cover / Fascia/Service and Repair/Rear Bumper Fascia - Installation. 5. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Sensor > Component Information > Locations > Page 8365 Pedal Positioning Sensor: Diagrams Connector - (INSTRUMENT PANEL) 3 WAY SENSOR-ADJUSTABLE PEDALS - (INSTRUMENT PANEL) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Locations > Page 8369 Pedal Positioning Switch: Diagrams Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-ADJUSTABLE PEDALS - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Service and Repair > Removal Pedal Positioning Switch: Service and Repair Removal REMOVAL 1. Remove the lower drivers side bezel. 2. Disconnect the electrical connector (2) from the adjustable pedal switch (1). 3. Remove the switch from the lower drivers side bezel by squeezing the retaining clips together and pushing the switch outwards Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Pedal Positioning Switch > Component Information > Service and Repair > Removal > Page 8372 Pedal Positioning Switch: Service and Repair Installation INSTALLATION 1. Install the switch (1) to the lower drivers side bezel by pushing the switch inwards seating the retaining clips to the lower drivers side bezel. 2. Reconnect the electrical connector (2) to the adjustable pedal switch (1). 3. Install the lower drivers side bezel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Locations > Left Remote Radio Switch > Page 8377 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way Remote Switch: Diagrams Left Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-LEFT - (STEERING WHEEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Diagrams > Left Remote Radio Switch (Steering Wheel) 2 Way > Page 8380 Remote Switch: Diagrams Right Remote Radio Switch (Steering Wheel) 2 Way Connector - (STEERING WHEEL) 2 WAY SWITCH-REMOTE RADIO-RIGHT - (STEERING WHEEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Remote Radio Switches - Description Remote Switch: Description and Operation Remote Radio Switches - Description DESCRIPTION Two rocker-type switches are mounted in the sides of the rear (instrument panel side) steering wheel trim cover. The switch on the left spoke is the seek switch and has seek up, seek down, and preset station advance functions. The switch on the right spoke is the volume control switch and has volume up, and volume down functions. The switch on the right spoke also includes a "mode" control that allows the driver to sequentially select AM radio, FM radio, cassette player or CD player. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Remote Radio Switches - Description > Page 8383 Remote Switch: Description and Operation Remote Radio Switches - Operation OPERATION The six switches in the two remote radio switch units are normally open, resistor multiplexed momentary switches that are hard wired to the Instrument cluster through the clockspring. The instrument cluster sends a five volt reference signal to both switch units on one circuit, and senses the status of all of the switches by reading the voltage drop on a second circuit. When the instrument cluster senses an input (voltage drop) from any one of the remote radio switches, it sends the proper switch status messages on the Controller Area Network (CAN) data bus to the radio. The electronic circuitry within the radio is programmed to respond to these remote radio switch status messages by adjusting the radio settings as requested. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 8384 Remote Switch: Testing and Inspection REMOTE RADIO SWITCHES Any diagnosis of the audio system should begin with the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Remove the remote radio switch(es) (1) and (2) from the steering wheel See: Service and Repair/Remote Radio Switches - Removal. 2. Use an ohmmeter to check the switch resistances as shown in the Remote Radio Switch Test table. If the remote radio switch resistances are not as indicated, replace the inoperative switch. REMOTE RADIO SWITCH TEST Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches Removal Remote Switch: Service and Repair Remote Radio Switches - Removal REMOVAL WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. 2. Remove the driver side airbag (5) from the steering wheel (1). See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag - Removal. 3. Remove the speed control switch (3) or (6) located on the same side of the steering wheel as the remote radio switch that is being serviced. See: Cruise Control/Cruise Control Switch/Service and Repair/Speed Control Switch - Removal. 4. Disconnect the steering wheel wire harness connector from the connector receptacle of the remote radio switch. 5. Disengage the four remote radio switch latches that secure the switch to the inside of the mounting hole in the steering wheel rear trim cover. 6. From the outside of the steering wheel rear trim cover, remove the remote radio switch (2) from the trim cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair > Remote Radio Switches Removal > Page 8387 Remote Switch: Service and Repair Remote Radio Switches - Installation INSTALLATION 1. Position the remote radio switch to the mounting hole on the outside of the steering wheel rear trim cover. Be certain that the connector receptacle is oriented toward the bottom of the switch and pointed toward the center of the steering wheel. 2. Press firmly and evenly on the remote radio switch until each of the switch latches is fully engaged in the mounting hole of the steering wheel rear trim cover. 3. Reconnect the steering wheel wire harness connector to the connector receptacle of the remote radio switch. 4. Install the speed control switch onto the steering wheel. See: Cruise Control/Cruise Control Switch/Service and Repair/Speed Control Switch Installation. 5. Install the driver side airbag to the steering wheel. See: Restraint Systems/Air Bag Systems/Air Bag/Service and Repair/Removal and Replacement/Driver Air Bag - Installation. 6. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations > Page 8391 Vacuum Brake Booster Diaphragm Position Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 3 WAY SENSOR-BOOSTER TRAVEL (HEV) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Description DESCRIPTION The travel sensor (7) is mounted on power brake booster (1) below and to the left of the master cylinder, and has one electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description > Page 8394 Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Operation OPERATION The travel sensor is a three-wire potentiometer that varies the voltage output as the position of the booster diaphragm changes. The RBS module uses the position information to determine the amount of booster movement and hydraulic brake application. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor - Removal REMOVAL 1. Disconnect the electrical connector (2) from the travel sensor (1). NOTE: The retainer clip does not need to be removed, only pushed up slightly to disengage the tabs on the sensor. 2. Using a small screw driver (4) or another suitable tool, push up on the retainer clip (2) and pull the travel sensor (3) from the power brake booster (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal > Page 8397 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor Installation INSTALLATION NOTE: When replacing the travel sensor, the Anti-Lock Brake Module (ABM) must be initialized using the scan tool. To initialize the ABM perform the ABS VERIFICATION TEST - HEV. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test . NOTE: Verify that the surface is clean, the old O-ring is removed, and the new O-ring is properly positioned on the sensor. 1. With a slight twisting motion, push the travel sensor (3) into the power brake booster (1). There should be a slight snapping sound as the retainer clip (3) seats into position. 2. Verify that the travel sensor retainer clip (3) snapped into place. 3. Connect the electrical connector (2) to the travel sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Towing Towing Information: Service and Repair Towing SPECIFICATIONS In this article you will find safety tips and information on limits to the type of towing you can reasonably do with the vehicle. Before towing a trailer carefully review this information to tow the load as efficiently and safely as possible. To maintain warranty coverage, follow the requirements and recommendations concerning vehicles used for trailer towing. Common Towing Definitions The following trailer towing related definitions will assist you in understanding the following information: Gross Vehicle Weight Rating (GVWR) The GVWR is the total allowable weight of the vehicle. This includes driver, passengers, cargo and tongue weight. The total load must be limited so that you do not exceed the GVWR. Gross Trailer Weight (GTW) The Gross Trailer Weight (GTW) is the weight of the trailer plus the weight of all cargo, consumables and equipment (permanent or temporary) loaded in or on the trailer in its "loaded and ready for operation" condition. The recommended way to measure GTW is to put the fully loaded trailer on a vehicle scale. The entire weight of the trailer must be supported by the scale. Gross Combination Weight Rating (GCWR) The Gross Combination Weight Rating (GCWR) is the total permissible weight of the vehicle and trailer when weighed in combination. (Note that GCWR ratings include a 150 lbs (68 kg) allowance for the presence of a driver). Gross Axle Weight Rating (GAWR) The GAWR is the maximum capacity of the front and rear axles. Distribute the load over the front and rear axles evenly. Make sure that you do not exceed either front or rear GAWR. WARNING: It is important that you do not exceed the maximum front or rear GAWR. A dangerous driving condition can result if either rating is exceeded. Failure to follow these instructions may result in serious or fatal injury. Tongue Weight (TW) The downward force exerted on the hitch ball by the trailer is the tongue weight. In most cases it should not be less than 10% or more than 15% of the trailer load. You must consider this as part of the load on the vehicle. Frontal Area The maximum height and maximum width of the front of a trailer. TSC (Trailer Sway Control) - If Equipped - Trailer Sway Control - Electronic TSC uses sensors in the vehicle to recognize a swaying trailer and will take the appropriate actions to attempt to stop the sway. The system will reduce engine power and apply individual brakes that will counteract the sway of the trailer. TSC will become active automatically once the swaying trailer is recognized. No driver action is required. TSC cannot stop all trailers from swaying. Always use caution when towing a trailer and follow the tongue weight recommendations. Even if the vehicle is equipped with electronic TSC, mechanical sway control is recommended when appropriate for the size of the trailer. Trailer Sway Control - Mechanical The trailer sway control is a telescoping link that can be installed between the hitch receiver and the trailer tongue that typically provides adjustable friction associated with the telescoping motion to dampen any unwanted trailer swaying motions while traveling. Weight-Carrying Hitch A weight-carrying hitch supports the trailer tongue weight, just as if it were luggage located at a hitch ball or some other connecting point of the vehicle. These kind of hitches are the most popular on the market today and they're commonly used to tow small- and medium-sized trailers. Weight-Distributing Hitch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Towing > Page 8403 A weight-distributing system works by applying leverage through spring (load) bars. They are typically used for heavier loads, to distribute trailer tongue weight to the tow vehicle's front axle and the trailer axle(s). When used in accordance with the manufacturers' directions, it provides for a more level ride, offering more consistent steering and brake control thereby enhancing towing safety. The addition of a friction/hydraulic sway control also dampens sway caused by traffic and crosswinds and contributes positively to tow vehicle and trailer stability. trailer sway control and a weight distributing (load equalizing) hitch are recommended for heavier tongue weights and may be required depending on vehicle and trailer configuration/loading to comply with Gross Axle Weight Rating (GAWR) requirements. WARNING: An improperly adjusted Weight-Distributing Hitch system may reduce handling, stability, braking performance, and could result in an accident. Weight-Distributing Systems may not be compatible with surge brake couplers. Consult with the hitch and trailer manufacturer or a reputable recreational vehicle dealer for additional information. Failure to follow these instructions may result in serious or fatal injury. Fifth-Wheel Hitch A fifth-wheel hitch is a special high platform with a coupling that mounts over the rear axle of the tow vehicle in the truck bed. Connects a vehicle and fifth-wheel trailer with a coupling king pin. Gooseneck Hitch The gooseneck hitch employs a pivoted coupling arm which attaches to a ball mounted in the bed of a pickup truck. The coupling arm connects to the hitch mounted over the rear axle in the truck bed. Trailer Hitch Classification The rear bumper is intended to tow trailers up to 2,000 lbs (907 kg) without added equipment or alterations to the standard equipment. the vehicle may be factory equipped for safe towing of trailers weighing over 2,000 lbs (907 kg) with the optional Trailer Tow Prep Package. See the authorized dealer for package content. The following chart provides the industry standard for the maximum trailer weight a given trailer hitch class can tow and should be used to assist you in selecting the correct trailer hitch for the intended towing condition. Refer to Trailer Towing Weights (Maximum Trailer Weight Ratings) for the website address that contains the necessary information for the specific drivetrain. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Towing > Page 8404 All trailer hitches should be professionally installed on the vehicle. Trailer Towing Weights (Maximum Trailer Weight Ratings) Trailer and Tongue Weight Always load a trailer with 60% to 65% of the weight in the front of the trailer. This places 10% to 15% of the Gross Trailer Weight (GTW) on the tow hitch of the vehicle. Loads balanced over the wheels or heavier in the rear can cause the trailer to sway severely side to side which will cause loss of control of vehicle and trailer. Failure to load trailers heavier in front is the cause of many trailer accidents. Never exceed the maximum tongue weight stamped on the bumper or trailer hitch. Consider the following items when computing the weight on the rear axle of the vehicle: - The tongue weight of the trailer. - The weight of any other type of cargo or equipment put in or on the vehicle. - The weight of the driver and all passengers. NOTE: Remember that everything put into or on the trailer adds to the load on the vehicle. Also, additional factory-installed options, or dealer-installed options, must be considered as part of the total load on the vehicle. See: Maintenance/Wheels and Tires/Service and Repair/Procedures Tire and Loading Information placard in the Tire Safety Information section. Towing Requirements To promote proper break-in of the new vehicle drivetrain components the following guidelines are recommended: CAUTION: - Avoid towing a trailer for the first 500 mi (805 km) of vehicle operation. Doing so may damage the vehicle. - During the first 500 mi (805 km) of trailer towing, limit the speed to 50 mph (80 km/h). When towing a trailer, never exceed the GAWR, or GCWR, ratings. WARNING: Improper towing can lead to an injury accident. Follow these guidelines to make the trailer towing as safe as possible: Make certain that the load is secured in the trailer and will not shift during travel. When trailering cargo that is not fully secured, dynamic load shifts can occur that may be difficult for the driver to control. Failure to follow these instructions may result in serious or fatal injury. - When hauling cargo or towing a trailer, do not overload the vehicle or trailer. Overloading can cause a loss of control, poor performance or damage to brakes, axle, engine, transmission, steering, suspension, chassis structure or tires. - Safety chains must always be used between the vehicle and trailer. Always connect the chains to the frame or hook retainers of the vehicle hitch. Cross the chains under the trailer tongue and allow enough slack for turning corners. - Vehicles with trailers should not be parked on a grade. When parking, apply the parking brake on the tow vehicle. Put the tow vehicle automatic transmission in PARK. With a manual transmission, shift the transmission into REVERSE. And with four-wheel drive vehicles, make sure the Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Towing > Page 8405 transfer case is not in NEUTRAL. Always, block or "chock" the trailer wheels. - GCWR must not be exceeded. - Total weight must be distributed between the tow vehicle and the trailer so that the following four ratings are not exceeded: - GVWR - GTW - GAWR - Tongue weight rating for the trailer hitch utilized (This requirement may limit the ability to always achieve the 10% to 15% range of tongue weight as a percentage of total trailer weight). Towing Requirements - Tires - Do not attempt to tow a trailer while using a compact spare tire. - Proper tire inflation pressures are essential to the safe and satisfactory operation of the vehicle. Refer to the Tires-General Information section on Tire Pressures for proper tire inflation procedures. - Also, check the trailer tires for proper tire inflation pressures before trailer usage. - Check for signs of tire wear or visible tire damage before towing a trailer.See: Maintenance/Wheels and Tires/Tires/Description and Operation section on Tread Wear Indicators for the proper inspection procedure. - When replacing tires See: Maintenance/Wheels and Tires/Tires/Description and Operation section on Replacement Tires for proper tire replacement procedures. Replacing tires with a higher load carrying capacity will not increase the vehicle's GVWR and GAWR limits. Towing Requirements - Trailer Brakes - Do not interconnect the hydraulic brake system or vacuum system of the vehicle with that of the trailer. This could cause inadequate braking and possible personal injury. - An electronically actuated trailer brake controller is required when towing a trailer with electronically actuated brakes. When towing a trailer equipped with a hydraulic surge actuated brake system, an electronic brake controller is not required. - Trailer brakes are recommended for trailers over 1,000 lbs (454 kg) and required for trailers in excess of 2,000 lbs (907 kg). CAUTION: If the trailer weighs more than 454 kg (1,000 lbs) loaded, it should have its own brakes and they should be of adequate capacity. Failure to do this could lead to accelerated brake lining wear, higher brake pedal effort, longer stopping distances and may result in serious or fatal injury. WARNING: Do not connect trailer brakes to the vehicle's hydraulic brake lines. It can overload the brake system and cause it to fail. You might not have brakes when you need them and could have an accident. Towing any trailer will increase the stopping distance. When towing you should allow for additional space between the vehicle and the vehicle in front of you. Failure to follow these instructions may result in serious or fatal injury. Towing Requirements - Trailer Lights AND Wiring Whenever you pull a trailer, regardless of the trailer size, stop lights and turn signals on the trailer are required for motoring safety. The Trailer Tow Package may include a 4- and 7-pin wiring harness. Use a factory approved trailer harness and connector. NOTE: Do not cut or splice wiring into the vehicle's wiring harness. The electrical connections are all complete to the vehicle but you must mate the harness to a trailer connector. Refer to the illustrations and. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Towing > Page 8406 Towing Tips Before setting out on a trip, practice turning, stopping and backing the trailer in an area away from heavy traffic. If using a manual transmission vehicle for trailer towing, all starts must be in FIRST gear to avoid excessive clutch slippage. Towing Tips - Automatic Transmission The D range can be selected when towing. However, if frequent shifting occurs while in this range, the TOW HAUL feature should be selected. NOTE: Using the TOW HAUL feature while operating the vehicle under heavy operating conditions will improve performance and extend transmission life by reducing excessive shifting and heat build up. This action will also provide better engine braking. The automatic transmission fluid and filter should be changed if you REGULARLY tow a trailer for more than 45 minutes of continuous operation. See: Maintenance for transmission fluid change intervals. NOTE: Check the automatic transmission fluid level before towing. Towing Tips - Tow/Haul (If Equipped) To reduce potential for automatic transmission overheating, turn the TOW HAUL feature ON when driving in hilly areas or shift the transmission to Drive position 2 on more severe grades. Towing Tips - Electronic Speed Control (If Equipped) - Don't use in hilly terrain or with heavy loads. - When using the speed control, if you experience speed drops greater than 10 mph (16 km/h), disengage until you can resume cruising speed. - Use speed control in flat terrain and with light loads to maximize fuel efficiency. Towing Tips - Cooling System To reduce potential for engine and transmission overheating, take the following actions: - City Driving - When stopped for short periods of time, put transmission in neutral and increase engine idle speed. - Highway Driving - Reduce speed. - Air Conditioning - Turn off temporarily. - Refer to Cooling System Operating information in the Maintenance section for more information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Towing > Page 8407 Towing Information: Service and Repair Towing Recommendations TOWING RECOMMENDATIONS HEV Vehicles CAUTION: The manufacturer recommends towing with all wheels OFF the ground. Acceptable methods are to tow the vehicle on a flat bed or with one end of the vehicle raised and the opposite end on a towing dolly. A vehicle equipped with SAE- approved wheel lift-type towing equipment can be used to tow all vehicles. When towing a 4WD vehicle using a wheel-lift towing device, use tow dollies under the opposite end of the vehicle. A vehicle with a flat bed device can also be used to transport a disabled vehicle. SAFETY PRECAUTIONS CAUTION: The following safety precautions must be observed when towing a vehicle: - Secure loose and protruding parts. - Always use a safety chain system that is independent of the lifting and towing equipment. - Do not allow towing equipment to contact the disabled vehicle's fuel tank. - Do not allow anyone under the disabled vehicle while it is lifted by the towing device. - Do not allow passengers to ride in a vehicle being towed. - Always observe state and local laws regarding towing regulations. - Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists. - Do not attach tow chains, T-hooks, or J-hooks to a bumper, steering linkage, drive shafts or a non-reinforced frame hole. - Do not tow a heavily loaded vehicle. Use a flat bed device to transport a loaded vehicle. GROUND CLEARANCE CAUTION: If vehicle is towed with wheels removed, install lug nuts to retain brake drums or rotors. Raise the towed vehicle until lifted wheels are a minimum 100 mm (4 in) from the ground. Be sure there is adequate distance above the ground at the opposite end of the vehicle, especially when towing over rough terrain or steep rises in the road. RAMP ANGLE If towing with flat bed equipment, the approach ramp angle should not exceed 15 degrees. TOWING WHEN KEYS ARE NOT AVAILABLE When the vehicle is locked and keys are not available, tow with flat bed equipment. A wheel-lift device can be used on 4WD vehicles provided all the wheels are lifted off the ground using tow dollies. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Towing > Page 8408 Towing Information: Service and Repair Recreational Towing (Behind Motorhome, etc.) RECREATIONAL TOWING (BEHIND MOTORHOME, ETC.) OF 4X4 VEHICLES HEV Vehicles CAUTION: Recreational towing of hybrid models is not allowed. Towing the vehicle with the transmission in neutral can cause severe transmission damage. Removal of the driveshaft for towing is not recommended since this allows transmission fluid to leak out. Non-HEV Vehicles WARNING: You or others could be injured if you leave the vehicle unattended with the transfer case in the Neutral (N) position without first fully engaging the parking brake. The transfer case Neutral (N) position disengages both the front and rear driveshafts from the powertrain and will allow the vehicle to move despite the transmission position. The parking brake should always be applied when the driver is not in the vehicle. Failure to follow these instructions may result in possible serious or fatal injury. CAUTION: Internal damage to the transfer case will occur if a front or rear wheel lift is used when recreational towing. NOTE: Because of the design of the transfer cases, only use vehicles equipped with a NV 244 Generation II transfer case should be used for recreational towing. NOTE: The NV 244 Generation II transfer case must be shifted into Neutral (N) for recreational towing. The Neutral (N) selection button is located on the lower left hand corner of the 4WD control switch. Shifts into and out of transfer case Neutral (N) can take place with the selector switch in any mode position. NOTE: If the vehicle is to be towed for multiple days or one day for an eight hour or above duration, disconnect and isolate the battery to prevent discharge due to the illumination of the odometer and PRNDL light. Reset the radio, clock and stations after the negative battery cable is reinstalled. Shifting into Neutral (N) Use the following procedure to prepare your vehicle for recreational towing: CAUTION: It is necessary to follow these steps to be certain that the transfer case is fully in Neutral (N) before recreational towing to prevent damage to internal parts. - Bring vehicle to a complete stop. - Turn the engine OFF. - Place the ignition key in the ON position. - Press the brake pedal. - Shift the automatic transmission to Neutral (N) or press the clutch on manual transmission. - Using the point of a ballpoint pen or similar object, press the recessed transfer case Neutral (N) button for four seconds. - After shift is completed and the Neutral (N) light comes on release Neutral (N) button. - Start the engine. - Shift the automatic transmission into Reverse (R). - Release the brake pedal for five seconds and make sure that there is no vehicle movement. - Repeat steps 9 and 10 with the transmission in Drive (D). - Turn the engine off and place the ignition key to the unlocked OFF position. - Shift the automatic transmission into Park (P). - Attach the vehicle to tow vehicle with a tow bar. NOTE: Items 1 through 5 are requirements that must be met prior to pressing the Neutral (N) selection button, and must continue to be met until the four seconds elapses and the shift has been completed. If any of these requirements (with the exception of 3 - Key on) are not met prior to pressing the Neutral (N) button or are no longer met during the four second timer, then the Neutral (N) indicator light flashes continuously until all requirements are met or until the Neutral (N) button is released. NOTE: The ignition key must be on for a shift to take place and for the position indicator lights to be operable. If the key is not on, the shift will not take place and no position indicator lights will be on or flashing. NOTE: Flashing neutral (N) position indicator light indicates that shift requirements have not been met. CAUTION: Damage to the transmission may occur if the transmission is shifted into Park (P) with the transfer case in Neutral (N) and the engine running. With the transfer case in Neutral (N), make sure the engine is off prior to shifting the transmission into Park (P). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Towing > Page 8409 Shifting out of Neutral (N) Use the following procedure to prepare your vehicle for normal usage: - Bring the vehicle to a complete stop. - Turn the engine off. - Place the ignition key in the ON position. - Press brake pedal. - Shift the automatic transmission to Neutral (N) or press the clutch on a manual transmission. - Using the point of a ballpoint pen or similar object, press the recessed transfer case Neutral (N) button for one second. - After the Neutral (N) indicator light turns off release the Neutral (N) button. - After the Neutral (N) button has been released the transfer case shifts to the position identified by the selector switch. - Shift the automatic transmission into Drive (D), or release the clutch on a manual transmission. NOTE: Items 1 through 5 are requirements that must be met prior to pressing the Neutral (N) selection button, and must continue to be met until one second elapses and the shift has been completed. If any of these requirements (with the exception of 3 - key on) are not met prior to pressing the Neutral (N) button or are no longer met during the one second time, then all of the mode position indicator lights flashes continuously until all requirements are met or until the Neutral (N) button is released. NOTE: The ignition key must be on for a shift to take place and for the position indicator lights to be operable. If the key is not on, the shift will not take place and no position indicator lights will be on or flashing. NOTE: Flashing neutral (N) position indicator light indicates that shift requirements have not been met. CAUTION: - Do not use a bumper mounted clamp-on tow bar on your vehicle. The bumper face bar will be damaged. - Do not disconnect the rear driveshaft because fluid will leak from the transfer case and damage internal parts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Information > System Information > Service and Repair > Towing > Page 8410 Towing Information: Service and Repair Four Wheel Drive Towing FOUR WHEEL DRIVE TOWING Chrysler Corporation recommends that a vehicle be transported on a flat-bed device. A Wheel-lift device can be used provided all the wheels are lifted off the ground using tow dollies. WARNING: When towing a disabled vehicle and the drive wheels are secured in a wheel lift or tow dollies, ensure the transmission is in the park position. CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To avoid component damage, a wheel-lift towing vehicle or a flat-bed hauling vehicle is recommended. FOUR WHEEL DRIVE TOWING - REAR END LIFTED WARNING: Ensure vehicle is on a level surface or the wheels are blocked to prevent vehicle from rolling. 1. Attach wheel lift device to front wheels. 2. Place the transmission in neutral. 3. Raise the front of the vehicle off the ground and install tow dollies under front wheels. 4. Attach wheel lift device to rear wheels and raise vehicle to towing position. 5. Attach safety chains to frame rails. Route chains so not to interfere with tail pipe when vehicle is lifted. 6. Turn the ignition switch to the OFF position to unlock the steering wheel. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. 7. Secure steering wheel in straight ahead position with a clamp device designed for towing. 8. Place the transmission in park. FOUR WHEEL DRIVE TOWING - FRONT END LIFTED WARNING: Ensure vehicle is on a level surface or the wheels are blocked to prevent vehicle from rolling. 1. Attach wheel lift device to rear wheels. 2. Place the transmission in neutral. 3. Raise the rear of the vehicle off the ground and install tow dollies under rear wheels. 4. Attach wheel lift device to front wheels and raise vehicle to towing position. 5. Attach the safety chains. CAUTION: Do not use steering column lock to secure steering wheel during towing operation. 6. Turn the ignition switch to the OFF position to unlock the steering wheel. 7. Secure steering wheel in straight ahead position with a clamp device designed for towing. 8. Place the transmission in park. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair > Tow Hook(s) - Removal Towing Hook / Bracket: Service and Repair Tow Hook(s) - Removal REMOVAL 1. Remove the front body mount bolt (1). 2. Remove the nuts (3) and remove the tow hook. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Towing Hook / Bracket > Component Information > Service and Repair > Tow Hook(s) - Removal > Page 8415 Towing Hook / Bracket: Service and Repair Tow Hook(s) - Installation INSTALLATION 1. Install the support brackets and install the bumper support nuts (3). 2. Tighten the nuts (3) to 109 Nm (80 ft. lbs.). 3. Install the front body mount bolt (1) and tighten to 81 Nm (60 ft. lbs.). 4. Install the support bracket (2) nuts (3) and tighten to 109 Nm (80 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8421 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8422 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8423 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8424 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8425 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8426 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8427 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8428 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8429 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8430 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8431 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8432 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8433 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8434 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8435 Trailer Connector: Connector Views Wiring-Trailer Tow 7-Way Connector - (CHASSIS) 7 WAY WIRING-TRAILER TOW 7-WAY - (CHASSIS) 7 WAY Trailer Tow Wiring 4 Way (Headlamp And Dash) 4 Way Connector - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8436 WIRING-TRAILER TOW 4-WAY - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8437 Trailer Connector: Electrical Diagrams TRAILER TOW - Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8438 Trailer Tow 8W-54-01 Trailer Tow 8W-54-02 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8439 Trailer Tow 8W-54-03 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Description and Operation > Trailer Tow Wiring - Description Trailer Connector: Description and Operation Trailer Tow Wiring - Description DESCRIPTION Vehicles equipped with a factory-installed trailer tow package include an electric trailer brake wiring provision that terminates at a connector located on top of the large body harness connection under the instrument panel to the left of the brake pedal, as well as an electric trailer brake pigtail harness and an instruction card (2) that are stored in the glove box (1) when the vehicle is shipped from the factory. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Description and Operation > Trailer Tow Wiring - Description > Page 8442 Trailer Connector: Description and Operation Trailer Tow Wiring - Operation OPERATION If an aftermarket electric brake controller is used, the electric brake pigtail harness supplied will make installation easier. The connection (blue 4-way connector) for the harness is located under the instrument panel to the left of the brake pedal on top of the large body harness connection. Refer to the appropriate wiring information. The battery line of this harness may be used to charge the trailer battery. However, a battery isolation unit is not supplied and the trailer battery may discharge the truck battery when the engine is not running. The battery line is protected by a fuse or a circuit breaker. Refer to the vehicle glove box for type, location, and ampere rating. The trailer tow connectors as well as the hard wired inputs and outputs of the connectors may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Service and Repair > Trailer Tow Connector - Removal Trailer Connector: Service and Repair Trailer Tow Connector - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Reach behind the bracket (1) on the trailer hitch receiver to access and disconnect the connector (3) of the body wire harness from the connector receptacle on the back of the trailer tow connector housing (2). 3. Reach behind the bracket (2) on the trailer hitch receiver to compress each of the two spring clips (1) on the trailer tow connector housing (3) far enough to push the housing out through the face of the bracket. 4. Remove the trailer tow connector from the bracket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Service and Repair > Trailer Tow Connector - Removal > Page 8445 Trailer Connector: Service and Repair Trailer Tow Connector - Installation INSTALLATION 1. Insert the trailer tow connector (3) into the bracket (2) on the trailer hitch receiver with the 7-pin connector oriented toward the outboard side of the bracket. 2. Using hand pressure, press the connector firmly and evenly into the bracket until both spring clips (1) on the connector housing snap into place on the back side of the bracket. 3. Reach behind the bracket (1) to access and reconnect the connector (3) of the body wire harness to the connector receptacle on the back of the trailer tow connector housing (2). 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch - Removal Trailer Hitch: Service and Repair Trailer Hitch - Removal REMOVAL 1. Remove the rear bumper. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Reinforcement/Service and Repair/Rear Bumper Support - Removal. 2. Remove the rear cab to frame bolts (3) and rebound cushions (2) to remove the front hitch bolt. 3. Support trailer hitch on a suitable lifting device. 4. Disconnect the trailer electrical wiring electrical connector. 5. Remove the bolts (3 and 5) and nuts (2) attaching trailer hitch (4) to frame rails (1). 6. Separate trailer hitch (4) from vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch - Removal > Page 8450 Trailer Hitch: Service and Repair Trailer Hitch - Installation INSTALLATION 1. Position trailer hitch on vehicle. 2. Install the bolts and nuts (2, 3 and 5) attaching trailer hitch to frame rail and tighten to 183 Nm (135 ft. lbs.). 3. Connect the trailer wiring electrical connector. 4. Install the rear body rebound cushions (2) and cab mounting bolts (3) and tighten to 81 Nm (60 ft. lbs.). 5. Install the rear bumper. See: Body and Frame/Bumper/Rear Bumper/Rear Bumper Reinforcement/Service and Repair/Rear Bumper Support Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Trailer Tow Left and Right Relays are located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Diagrams > Relay-Trailer Tow-Left Trailer Lighting Relay: Diagrams Relay-Trailer Tow-Left Connector (IN IPM) RELAY-TRAILER TOW-LEFT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Diagrams > Relay-Trailer Tow-Left > Page 8456 Trailer Lighting Relay: Diagrams Relay-Trailer Tow-Right Connector (IN IPM) RELAY-TRAILER TOW-RIGHT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Locations Trailer Towing Relay: Locations Trailer Tow Left and Right Relays are located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Diagrams > Relay-Trailer Tow-Left Trailer Towing Relay: Diagrams Relay-Trailer Tow-Left Connector (IN IPM) RELAY-TRAILER TOW-LEFT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Diagrams > Relay-Trailer Tow-Left > Page 8462 Trailer Towing Relay: Diagrams Relay-Trailer Tow-Right Connector (IN IPM) RELAY-TRAILER TOW-RIGHT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description Trailer Towing Relay: Description and Operation Trailer Tow Relay - Description DESCRIPTION Vehicles equipped with an optional factory-installed trailer towing package have two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description > Page 8465 Trailer Towing Relay: Description and Operation Trailer Tow Relay - Operation OPERATION The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays as well as the hard wired inputs and outputs of the relays may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8471 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8472 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8473 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8474 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8475 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8476 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8477 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8478 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8479 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8480 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8481 Trailer Connector: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8482 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8483 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8484 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8485 Trailer Connector: Connector Views Wiring-Trailer Tow 7-Way Connector - (CHASSIS) 7 WAY WIRING-TRAILER TOW 7-WAY - (CHASSIS) 7 WAY Trailer Tow Wiring 4 Way (Headlamp And Dash) 4 Way Connector - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8486 WIRING-TRAILER TOW 4-WAY - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8487 Trailer Connector: Electrical Diagrams TRAILER TOW - Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8488 Trailer Tow 8W-54-01 Trailer Tow 8W-54-02 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 8489 Trailer Tow 8W-54-03 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Description and Operation > Trailer Tow Wiring - Description Trailer Connector: Description and Operation Trailer Tow Wiring - Description DESCRIPTION Vehicles equipped with a factory-installed trailer tow package include an electric trailer brake wiring provision that terminates at a connector located on top of the large body harness connection under the instrument panel to the left of the brake pedal, as well as an electric trailer brake pigtail harness and an instruction card (2) that are stored in the glove box (1) when the vehicle is shipped from the factory. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Description and Operation > Trailer Tow Wiring - Description > Page 8492 Trailer Connector: Description and Operation Trailer Tow Wiring - Operation OPERATION If an aftermarket electric brake controller is used, the electric brake pigtail harness supplied will make installation easier. The connection (blue 4-way connector) for the harness is located under the instrument panel to the left of the brake pedal on top of the large body harness connection. Refer to the appropriate wiring information. The battery line of this harness may be used to charge the trailer battery. However, a battery isolation unit is not supplied and the trailer battery may discharge the truck battery when the engine is not running. The battery line is protected by a fuse or a circuit breaker. Refer to the vehicle glove box for type, location, and ampere rating. The trailer tow connectors as well as the hard wired inputs and outputs of the connectors may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Service and Repair > Trailer Tow Connector - Removal Trailer Connector: Service and Repair Trailer Tow Connector - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Reach behind the bracket (1) on the trailer hitch receiver to access and disconnect the connector (3) of the body wire harness from the connector receptacle on the back of the trailer tow connector housing (2). 3. Reach behind the bracket (2) on the trailer hitch receiver to compress each of the two spring clips (1) on the trailer tow connector housing (3) far enough to push the housing out through the face of the bracket. 4. Remove the trailer tow connector from the bracket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Service and Repair > Trailer Tow Connector - Removal > Page 8495 Trailer Connector: Service and Repair Trailer Tow Connector - Installation INSTALLATION 1. Insert the trailer tow connector (3) into the bracket (2) on the trailer hitch receiver with the 7-pin connector oriented toward the outboard side of the bracket. 2. Using hand pressure, press the connector firmly and evenly into the bracket until both spring clips (1) on the connector housing snap into place on the back side of the bracket. 3. Reach behind the bracket (1) to access and reconnect the connector (3) of the body wire harness to the connector receptacle on the back of the trailer tow connector housing (2). 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Accessories and Optional Equipment > Voice Activation System > Voice Activation Module > Component Information > Locations > Page 8500 Voice Activation Module: Diagrams Connector - (INSTRUMENT PANEL) 22 WAY MODULE-HANDS FREE - (INSTRUMENT PANEL) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Front Control Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Locations > Front Control Module > Page 8507 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way Body Control Module: Diagrams Front Control Module (PDC AUX) 49 Way Connector - (PDC AUX) 49 WAY MODULE-FRONT CONTROL - (PDC AUX) 49 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 8510 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 8511 Body Control Module: Diagrams Front Control Module C1 (Headlamp And Dash) 24 Way Connector C1 - (HEADLAMP AND DASH) 24 WAY MODULE-FRONT CONTROL - (HEADLAMP AND DASH) 24 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 8512 Body Control Module: Diagrams Front Control Module C2 (Headlamp And Dash) 12 Way Connector C2 - (HEADLAMP AND DASH) 12 WAY MODULE-FRONT CONTROL - (HEADLAMP AND DASH) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 8513 Body Control Module: Diagrams Hybrid Gateway Module C1 (HEV) (Headlamp And Dash) 24 Way Connector C1 (HEV) - (HEADLAMP AND DASH) 24 WAY MODULE-HYBRID GATEWAY (HEV) - (HEADLAMP AND DASH) 24 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Front Control Module (PDC AUX) 49 Way > Page 8514 Body Control Module: Diagrams Hybrid Gateway Module C2 (HEV) (Headlamp And Dash) 12 Way Connector C2 (HEV) - (HEADLAMP AND DASH) 12 WAY MODULE-HYBRID GATEWAY (HEV) - (HEADLAMP AND DASH) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description Body Control Module: Description and Operation Gateway Module - Description DESCRIPTION Vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system have a Hybrid Gateway Module (HGM) (1) that is secured with three screws to the stamped steel Transmission Auxiliary Oil Pump (TAOP) control module mounting bracket located on the left hydro form (frame rail) near the back of the left front wheel housing within the engine compartment of the vehicle. Concealed within a hollow in the center of the die cast aluminum HGM housing is the electronic circuitry of the HGM, which includes a microprocessor and an electronic printed circuit board. A stamped metal cover plate (2) is sealed and secured to the HGM housing with four screws to enclose and protect the internal electronic circuitry and components. Two molded plastic electrical connectors (3), one containing 24 terminal pins and the other containing 12 terminal pins, exit the forward facing side of the HGM cover plate and are pointed downward. These terminal pins connect the HGM to the vehicle electrical system through two dedicated take outs and connectors of the headlamp and dash wire harness. The HGM housing has integral mounting flanges on two sides with three mounting holes in each flange. The mounting flange to the left of the connector receptacles is secured to the TAOP control module mounting bracket with two screws, while the flange on the right side is secured to the bracket with only one screw. The HGM cannot be repaired or adjusted and, if damaged or ineffective, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description > Page 8517 Body Control Module: Description and Operation Front Control Module - Description DESCRIPTION The Front Control Module (FCM) is a micro controller based module located in the left front corner of the engine compartment. The front control module mates to the power distribution center to form the Integrated Power Module (IPM). The IPM connects directly to the battery and provides the primary means of circuit protection and power distribution for all vehicle electrical systems. The front control module controls power to some of these vehicle systems electrical and electromechanical loads based on inputs received from hard wired switch inputs and data received on the CAN bus circuit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description > Page 8518 Body Control Module: Description and Operation Front Control Module - Operation OPERATION As messages are sent over the CAN bus circuit, the Front Control Module (FCM) reads these messages and controls power to some of the vehicles electrical systems by completing the circuit to ground (low side driver) or completing the circuit to 12 volt power (high side driver). The following functions are controlled by the FCM: - Front turn signals - Stop, turn signal and tail lamps - Front and rear hazard warning lamps - Headlamps - Fog Lamps - Daytime running lamps - if equipped - Horn - Windshield and liftgate wiper and washer systems - Transfer case shifting - Trailer tow wiring output - Rear window defroster power and timing - Air conditioning condenser cooling fan The FCM provides the following features for the above function: - It provides a illuminated approach feature that turns the headlamps on when the vehicle is unlocked with the Remote Keyless Entry (RKE) transmitter. - It flashes lamps in response to turn signal, RKE and Vehicle Theft Security System (VTSS) inputs. - It sounds the horn in response to RKE and VTSS inputs. - It turns off the horn in the event of excessively long operation that could otherwise damage the horn. - It turns off the windshield washer motor after 10 seconds of continuous operation to protect the motor. - It minimizes voltage variations to the headlamps to extend bulb life and to equalize the light output from the lamps, which might otherwise differ due to variations in wiring resistance. - If the headlamps are left on, it automatically turns them off after eight minutes to protect the battery from discharge.It monitors battery voltage and turns off non-essential functions such as the fog lamps, rear window defogger, and heated seats if necessary to conserve battery power. - It operates the high-beam headlamps at reduced intensity by pulse-width modulation of the power supply to provide the daytime running lamps. - It provides the variable delay intermittent windshield and liftgate wiper time delay features, and the vehicle speed sensitive windshield wiper delay variation. - It acts as a link between the CAN bus network for critical powertrain and anti-lock brake systems and the network for body and interior modules. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Description and Operation > Gateway Module - Description > Page 8519 Body Control Module: Description and Operation Gateway Module - Operation OPERATION The Hybrid Gateway Module (HGM) provides a communication interface between the electronic control modules (nodes) in the vehicle, as well as with the diagnostic scan tool connected to the Controller Area Network (CAN) data bus system and the nodes connected to the Hybrid Local Area Network (H-LAN) data bus system. The HGM is the central gateway that processes and transfers messages between the different bus systems. In addition, the HGM is Local Interface Network (LIN) bus compatible. It receives a direct input over the LIN bus from a humidity sensor secured to the inside rear view mirror mount on the inside of the windshield glass, which it then transmits over the CAN data bus to other electronic modules in the vehicle. The microprocessor-based HGM also provides input and output circuitry that responds to both digital and analog inputs and provides electronically controlled higher current load outputs through lower current relay drivers. The HGM uses On-Board Diagnostics (OBD). If the HGM detects a monitored system fault, it sets a Diagnostic Trouble Code (DTC) that can be retrieved with a diagnostic scan tool through the 16-way data link connector located on the driver side lower edge of the instrument panel. The HGM connects directly to a fused battery current input and to ground, so that it remains capable of operating, regardless of the ignition switch position. The hardwired inputs and outputs for the HGM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the HGM, the electronic controls or communication between other modules and devices that provide features of the Hybrid Electric Vehicle (HEV) control system. The most reliable, efficient and accurate means to diagnose the HGM, the electronic controls and communication related to HGM operation, requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Front Control Module (FCM) Intermittent Condition Test Body Control Module: Testing and Inspection Front Control Module (FCM) Intermittent Condition Test INTERMITTENT CONDITION For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. INTERMITTENT CONDITION NOTE: The conditions that set the DTC are not present at this time. The following list may help in identifying the intermittent condition. WARNING: When the engine is operating, do not stand in direct line with the fan. Do not put your hands near the pulleys, belts or fan. Do not wear loose clothing. Failure to follow these instructions may result in possible serious or fatal injury. 1. Perform any Technical Service Bulletins (TSBs) that may apply. 2. Review the scan tool Freeze Frame information. If possible, try to duplicate the conditions under which the DTC set. 3. Turn the ignition off. 4. Visually inspect the related wire harness. Wiggle the related wire harness and look for an interrupted signal on the affected circuit. Disconnect all the related harness connectors. Look for any chafed, pierced, pinched, partially broken wires and broken, bent, pushed out, or corroded terminals. 5. Perform a voltage drop test on the related circuits between the suspected inoperative component and the Anti-Lock Brake Module, Front Control Module, or Totally Integrated Power Module, which every applies to the circuits in questions. 6. Inspect and clean all Powertrain Control Module (PCM), APS, engine, and chassis grounds that are related to the most current DTC. 7. If numerous trouble codes were set, use a wire schematic and look for any common ground or supply circuits 8. For any Relay DTCs, actuate the Relay with the scan tool and wiggle the related wire harness to try to interrupt the actuation. 9. Use the scan tool to perform a System Test if one applies to failing component. 10. A co-pilot, data recorder, and/or lab scope should be used to help diagnose intermittent conditions. Were any problems found during the above inspections? Yes - Perform the necessary repairs. - Perform the APS VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/APS Verification Test. No - Test Complete. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Front Control Module (FCM) Intermittent Condition Test > Page 8522 Body Control Module: Testing and Inspection Wireless Control Module (WCM) Intermittent Condition Test WIRELESS CONTROL MODULE (WCM) INTERMITTENT TEST For a complete wiring diagram, refer to the Wiring Information See: Diagrams/Electrical Diagrams. 1. RECORD AND ERASE ALL WCM DIAGNOSTIC TROUBLE CODES (DTCS) Using a scan tool, record and erase all DTCs from the WCM. Monitor any active codes as you work through the following steps. - Review the code monitor and set conditions for any DTCs that are stored and attempt to reproduce the conditions listed. - Wiggle the wiring harness and connectors of the related circuit, sensor or component. - Turn the ignition off. Search for any Technical Service Bulletins (TSBs) that may apply. Was the source of the customer complaint found or did any DTCs appear and stay active? Yes - Make the appropriate repairs and perform the WIRELESS CONTROL MODULE (WCM) VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Wireless Control Module (WCM) Verification Test or select the correct DTC procedure. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures. No - Go To 2 2. ATTEMPT TO REPRODUCE THE CONDITION In the event the customer complaint cannot be duplicated due to an intermittent condition in the theft/security system, the following may aid in attempting to reproduce the condition. - Using the wiring diagram/schematic as a guide, inspect the wiring and connectors related to the stored code or component in question. - Look for chafed, pierced, pinched, or partially broken wires and broken, bent, pushed out, spread, corroded, or contaminated terminals. - If the customer concern was related to a specific fobik, ensure the fobik in question is used while attempting reproduce the condition. - Reconnect any disconnected components and harness connectors and ensure they are properly seated. - If numerous trouble codes were set, use a schematic and inspect any common ground or supply circuits. Was the source of the intermittent condition located? Yes - Make the appropriate repairs and perform the WIRELESS CONTROL MODULE (WCM) VERIFICATION TEST. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Wireless Control Module (WCM) Verification Test No - The problem cannot be found at this time. If repeated intermittent failures are encountered that cannot be reproduced and the condition has prompted multiple customer visits to the dealership, document any findings on the repair order. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Testing and Inspection > Front Control Module (FCM) Intermittent Condition Test > Page 8523 Body Control Module: Testing and Inspection Wireless Control Module (WCM) Pre-Diagnostic Procedure WIRELESS CONTROL MODULE (WCM) PRE-DIAGNOSTIC PROCEDURE Before attempting to repair any theft or security system, technicians should be familiar with and fully understand the system operation. See: Accessories and Optional Equipment/Antitheft and Alarm Systems/Description and Operation/Vehicle Theft Security System - Description. The following should be used as a checklist to be completed in its entirety prior to referencing specific Theft and Security Diagnostic Procedures. FOLLOW THE BASIC OUTLINE IN THE SIX-STEP TROUBLESHOOTING PROCEDURE - Verification of complaint - Verification of any related symptoms - Symptom analysis - Problem isolation - Repair of isolated problem - Verification of proper operation TAKE INTO ACCOUNT CURRENT VEHICLE CONDITION, REPAIR HISTORY, AND TECHNICAL SERVICE BULLETINS (TSBs) - Verify there are no outward signs of vehicle damage that could impact the proper operation of the theft or security system. Check for aftermarket vehicle accessories that may have been installed improperly or could interfere with the system - Check the vehicle repair history for repairs that may relate to the current condition. - Perform a check of current Technical Service Bulletins (TSB) for the system related to the customer concern. If a TSB applies, follow the procedure outlined in the TSB. DIAGNOSE ONLY THOSE FAILURES THAT ARE ACTIVE AND CAN BE REPRODUCED - Check the control module central to the subsystem that is exhibiting the condition for active Diagnostic Trouble Codes (DTCs). - For an intermittent failure that is not current at the time of vehicle inspection, refer to the WIRELESS CONTROL MODULE INTERMITTENT TEST See: Wireless Control Module (WCM) Intermittent Condition Test and document the event on the repair order. ADDRESS ACTIVE DTCS IN THE CORRECT ORDER - Low/High Voltage and Serial Data Loss of Communication Codes - Module Internal Failure and Configuration Mismatch Codes - Circuit specific DTC failures As a general rule, for any theft/security system control module that exhibits more than one active DTC, address the codes in the order indicated; should the malfunction still be present after conducting this Pre-diagnostic Procedure, technicians should continue to the appropriate DTC procedure or symptom diagnostic. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal Body Control Module: Service and Repair Gateway Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. A technician trained in proper Hybrid Electric Vehicle (HEV) service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Wait two minutes for the system capacitors to discharge before further service. 2. Unlatch and remove the Power Distribution Center (PDC) from the PDC mounting bracket on the left hydro form (frame rail) over the left front wheel house in the engine compartment. Move the PDC forward far enough to access the Hybrid Gateway Module (HGM) (1). 3. Remove the three screws (2) that secure the HGM to the Transmission Auxiliary Oil Pump (TAOP) control module mounting bracket (3) that is secured to the left hydro form near the back of the left front wheel house. 4. Disconnect the two headlamp and dash wire harness connectors (4) from the HGM connector receptacles located on the forward facing side of the module. 5. Remove the HGM from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal > Page 8526 Body Control Module: Service and Repair Gateway Module - Installation INSTALLATION 1. Position the Hybrid Gateway Module (HGM) (1) near the Transmission Auxiliary Oil Pump (TAOP) control module mounting bracket (3) that is secured to the left hydro form (frame rail) near the back of the left front wheel house in the engine compartment. 2. Reconnect the two headlamp and dash wire harness connectors (4) to the HGM connector receptacles located on the forward facing side of the module. 3. Position the HGM to the TAOP control module mounting bracket. 4. Install and tighten the three screws (2) that secure the HGM to the mounting bracket. Tighten the screws securely. 5. Reinstall the Power Distribution Center (PDC) onto the PDC mounting bracket on the left hydro form over the left front wheel house in the engine compartment. Be certain that each of the PDC latches is fully engaged with the mounting bracket. 6. Reconnect the battery negative cable. A technician trained in proper Hybrid Electric Vehicle (HEV) service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal > Page 8527 Body Control Module: Service and Repair Front Control Module - Removal REMOVAL 1. Disconnect the positive and negative battery cables from the battery. 2. Partially remove the Integrated Power Module (IPM) from the engine compartment. 3. Remove the front control module retaining screws. 4. Pull the front control module straight from the IPM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Gateway Module - Removal > Page 8528 Body Control Module: Service and Repair Front Control Module - Installation INSTALLATION 1. Press the Front Control Module (FCM) onto the Integrated Power Module (IPM). 2. Install the mounting fasteners. 3. Install the IPM. 4. Connect the positive and negative battery cables. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Auxiliary Step / Running Board > System Information > Description and Operation Auxiliary Step / Running Board: Description and Operation DESCRIPTION RUNNING BOARD Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Support Bracket - Removal Front Bumper Cover / Fascia: Service and Repair Fascia Support Bracket - Removal REMOVAL 1. Remove the front fascia. See: Lighting and Horns/Fog/Driving Lamp/Service and Repair/Fog Lamp - Removal. 2. Remove the front bolts next to the fog lights. 3. Disconnect the fog lamp electrical connectors, if equipped. 4. Release the tabs and remove the bumper. 5. Remove the fog lamps from the bumper as necessary, See: Lighting and Horns/Fog/Driving Lamp/Service and Repair/Fog Lamp - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Support Bracket - Removal > Page 8538 Front Bumper Cover / Fascia: Service and Repair Fascia Support Bracket - Installation INSTALLATION 1. Install the fog lamps into the bumper, if necessary, See: Lighting and Horns/Fog/Driving Lamp/Service and Repair/Fog Lamp - Removal. 2. Position the bumper onto the bumper support and seat the tabs fully. 3. Connect the fog lamp electrical connectors, if equipped. 4. Install the front bolts next to the fog lamps. 5. Install the fascia. See: Front Bumper Fascia Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Support Bracket - Removal > Page 8539 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia - Removal REMOVAL 1. Remove the wheel well splash shield screws. 2. Remove the two impact beam screws (1). 3. Remove the two air dam to wheel liner screws (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Support Bracket - Removal > Page 8540 4. Disconnect the fog lamp electrical connectors, if equipped. 5. Remove the fender screws (5). 6. Release the upper tabs (1) and remove the fascia. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Support Bracket - Removal > Page 8541 Front Bumper Cover / Fascia: Service and Repair Front Bumper Fascia - Installation INSTALLATION 1. Place the upper edge of fascia (1) onto the center support bracket under the grille and push on to snap retainers (2) together. 2. Insert the retainer pins (3) on the ends of the fascia into the holes in the lower fender flanges. 3. Install the screws (5). 4. Connect the fog lamp electrical connectors (6). 5. Install the screws (1). 6. Install the screws (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Support Bracket - Removal > Page 8542 7. Install the wheel liner screws. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia - Removal Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the screws (1) securing the fascia to the support brackets (2). 3. Remove the lower push pin fasteners (5). 4. Open the liftgate and remove the upper push pin fasteners (2). 5. Remove the fascia (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Rear Bumper Fascia - Removal > Page 8548 Rear Bumper Cover / Fascia: Service and Repair Rear Bumper Fascia - Installation INSTALLATION 1. Position the fascia (3) and install the push pin fasteners (2). 2. Install the lower push pin fasteners (5). 3. Install the screws (1) securing the fascia to the support brackets (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Cover - Removal Cowl Moulding / Trim: Service and Repair Cowl Panel Cover - Removal REMOVAL 1. Open the hood and remove the wiper arm nuts (3) and wiper arms (2). See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 2. Remove the two rear screws (1) and the five front push pins (5). 3. Remove the cowl grille (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Front Exterior Handle - Removal Front Door Exterior Handle: Service and Repair Front Exterior Handle - Removal REMOVAL 1. Remove the watershield. See: Front Door Panel/Service and Repair/Front Door Water Shield Removal. 2. Remove the bolt (3) and nut (2). Position aside the rear glass run channel (1). 3. Disconnect links 1 and 3 from the latch (4). 4. Remove the nut (4) and the handle (2). Disconnect the electrical connector (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Front Exterior Handle - Removal > Page 8562 5. Separate links 3 and 5 from clips 1 and 4. Remove the lock cylinder (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Front Exterior Handle - Removal > Page 8563 Front Door Exterior Handle: Service and Repair Front Exterior Handle - Installation INSTALLATION 1. Install links 3 and 5 into clips 1 and 4. Install the lock cylinder (2) into the exterior handle. 2. Connect the electrical connector (1) and position the handle (2) onto the door. 3. Install the nuts (4) and tighten to 5 Nm (44 in. lbs.). 4. Connect the links 1 and 3 to the latch (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Front Exterior Handle - Removal > Page 8564 5. Position the rear glass run channel back and install the nut and bolt. 6. Tighten the fasteners to 8 Nm (71 in. lbs.). 7. Install the watershield. See: Front Door Panel/Service and Repair/Front Door Water Shield - Installation. 8. Adjust the latch as needed. See: Front Door Latch/Adjustments Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Front Door Hinge: All Technical Service Bulletins Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8573 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8574 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Front Door Hinge: Customer Interest Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8580 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8581 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > Page 8582 Front Door Hinge: By Symptom Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > Page 8583 SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > Page 8584 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > Page 8585 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Front Door Hinge: > Page 8586 CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Front Door Hinge - Removal Front Door Hinge: Service and Repair Front Door Hinge - Removal REMOVAL 1. Remove the door. See: Service and Repair/Front Door - Removal 2. Using a grease pencil or equivalent, mark the outline of the door hinges on A-pillar end to aid installation. 3. Remove the bolts (5) and remove the hinges 2 and 4. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Front Door Hinge - Removal > Page 8589 Front Door Hinge: Service and Repair Front Door Hinge - Installation INSTALLATION 1. If necessary, paint replacement door hinge before installation. 2. Position door hinges 2 and 4 on hinge pillar using alignment marks and install the bolts (5). 3. Tighten the bolts to 28 Nm (21 ft. lbs.) using the sequence shown. NOTE: Right hand door shown, left hand door opposite. 4. Install the door. See: Service and Repair/Front Door - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Adjustments Front Door Latch: Adjustments ADJUSTMENT 1. Locate access hole (3) and remove the trim plug covering it. 2. Insert a 5/32-inch hex-wrench through hole and into adjustment screw. Loosen screw. 3. Operate outside handle several times to release any restriction because of misalignment. 4. Tighten adjustment screw to 3 Nm (30 in. lbs.). 5. Test handle for proper operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front Door Latch - Removal Front Door Latch: Service and Repair Front Door Latch - Removal REMOVAL 1. Remove the watershield. See: Front Door Panel/Service and Repair/Front Door Water Shield Removal 2. Remove the bolt (3) and nut (2) and position aside the rear glass run channel (1). 3. Remove the latch screws (5). 4. Disconnect the actuator rods (3). 5. Disconnect the electrical connectors (6) and remove the latch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front Door Latch - Removal > Page 8595 Front Door Latch: Service and Repair Front Door Latch - Installation INSTALLATION 1. Install the latch into the door. 2. Connect the electrical connectors (6). 3. Connect the actuator rods (3). 4. Install the screws and tighten to 10 Nm (85 in. lbs.). 5. Adjust the latch as needed. See: Adjustments 6. Position the rear glass run channel back and install the nut and bolt. 7. Tighten the fasteners to 8 Nm (70 in. lbs.). 8. Install the watershield. See: Front Door Panel/Service and Repair/Front Door Water Shield - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel - Removal Front Door Panel: Service and Repair Front Door Trim Panel - Removal REMOVAL 1. Remove the screws 5 and 7. CAUTION: Trim panel is attached to the door using hooks molded into the panel. Do not pull the trim panel straight off or damage to the panel and/or power switch assembly may occur. 2. Lift the trim panel up off the lock rod (4) and attachment hooks and separate the panel from the door slightly. 3. Disconnect the electrical connectors (1). 4. Disconnect the inside handle actuator rod (3) and remove the trim panel (6). 5. Remove the switch panel (1) if necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel - Removal > Page 8600 Front Door Panel: Service and Repair Front Door Trim Panel - Installation INSTALLATION 1. Install the switch assembly (1). 2. Position the trim panel (6) and connect the inside handle actuator rod (3). 3. Connect the electrical connectors (1). 4. Lift the trim panel up and onto the lock rod (4) and attachment hooks. 5. Install the screws 5 and 7. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel - Removal > Page 8601 Front Door Panel: Service and Repair Front Door Water Shield - Removal REMOVAL CAUTION: Do not allow the watershield or adhesive to become contaminated with dirt or other foreign substances. Do not damage the watershield during removal and installation. If the watershield becomes contaminated or damaged, replace the watershield. 1. Remove the speaker. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Speaker - Removal 2. Remove the door trim panel. See: Front Door Trim Panel - Removal 3. Separate the watershield (1) from the inner door panel (2) and off of the latch linkages. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Trim Panel - Removal > Page 8602 Front Door Panel: Service and Repair Front Door Water Shield - Installation INSTALLATION CAUTION: Do not allow the watershield or adhesive to become contaminated with dirt or other foreign substances. Do not damage the watershield during removal and installation. If the watershield becomes contaminated or damaged, replace the watershield. 1. Position the wire harness and actuator rods through the holes in the watershield. 2. Secure the watershield to the inner door panel. 3. Install the speaker. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Speaker - Installation 4. Install the trim panel. See: Front Door Trim Panel - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments Front Door Striker: Adjustments ADJUSTMENT 1. Using a grease pencil or equivalent, mark the position of the striker (2) to aid in adjustment. 2. Loosen the striker bolts (1). 3. Change the striker position to adjust the rear gap and flush measurement. 4. Tighten the bolts to 28 Nm (21 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Service and Repair > Door Latch Striker - Removal Front Door Striker: Service and Repair Door Latch Striker - Removal REMOVAL 1. Using a grease pencil or equivalent, mark the position of the striker (2). 2. Remove the bolts (1) and remove the striker. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Door Weatherstrip - Removal Front Door Weatherstrip: Service and Repair Door Weatherstrip - Removal REMOVAL 1. Insert special tool #9093 (2) between the outer belt molding (1) and glass at the rear. 2. Push down on outer belt molding (1) and rotate upper part of tool (2) outward from vehicle then lift up on molding (1) to disengage from locking tabs (3) working from back to front. NOTE: Typical outer belt molding design shown. 3. Slide molding out from under the side view mirror and remove. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Door Weatherstrip - Removal > Page 8612 Front Door Weatherstrip: Service and Repair Door Weatherstrip - Installation INSTALLATION 1. Position the outer belt molding onto the door and position forward under the side view mirror. Seat the molding fully. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor > Component Information > Testing and Inspection Front Door Window Motor: Testing and Inspection WINDOW MOTOR For complete circuit diagrams, refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the trim panel from the door with the inoperative power window. 2. Unplug the power window motor wire harness connector. Apply 12 volts across the motor terminals to check its operation in one direction. Reverse the connections across the motor terminals to check the operation in the other direction. If the window is in the full up or full down position, the motor will not operate in that direction by design. If OK, repair the circuits from the power window motor to the power window switch as required. If not OK, replace the inoperative motor. 3. If the motor operates in both directions, check the operation of the window glass and lift mechanism through its complete up and down travel. There should be no binding or sticking of the window glass or lift mechanism through the entire travel range. If not OK, check the window glass, tracks, and regulator for sticking, binding, or improper adjustment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal Front Door Window Regulator: Service and Repair Front Door Window Regulator - Removal REMOVAL 1. Remove the watershield. See: Front Door Panel/Service and Repair/Front Door Water Shield Removal. 2. Temporarily install the window switch and position the glass (1) to gain access to the regulator nuts (4). 3. Remove the nuts (4). 4. Secure the glass in the up position using a wood wedge or equivalent. 5. Remove the bolts (2) and loosen the remaining regulator bolts. 6. Separate the regulator (2) from the door panel (1) and disconnect the electrical connector (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal > Page 8620 Front Door Window Regulator: Service and Repair Front Door Window Regulator - Installation INSTALLATION 1. Position the regulator (2) into the door (1) and connect the electrical connector (3). 2. Position the regulator bolts into the keyhole slots and slide into place. 3. Install the remaining regulator bolts (2). 4. Tighten the bolts to 9 Nm (80 in. lbs.). 5. Position the glass (1) onto the door regulator (3). 6. Install the nuts (4) and tighten to 9 Nm (80 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal > Page 8621 7. Install the watershield. See: Front Door Panel/Service and Repair/Front Door Water Shield Installation 8. Perform the Clear/Relearn procedure. See: Windows and Glass/Windows/Testing and Inspection/Programming and Relearning Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Exterior Door Handle - Removal Rear Door Exterior Handle: Service and Repair Rear Exterior Door Handle - Removal REMOVAL 1. Remove the watershield. See: Rear Door Panel/Service and Repair/Water Shield - Removal. 2. Disconnect the link from the latch. 3. Remove the nut (4) and the handle (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Rear Exterior Door Handle - Removal > Page 8628 Rear Door Exterior Handle: Service and Repair Rear Exterior Door Handle - Installation INSTALLATION 1. Position the handle (1) into the door and install the nuts (4). 2. Tighten the nuts to 5 Nm (45 in. lbs.). 3. Connect the link. 4. Install the watershield. See: Rear Door Panel/Service and Repair/Water Shield - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Rear Door Hinge: Customer Interest Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8637 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > Customer Interest for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8638 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises Rear Door Hinge: All Technical Service Bulletins Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8644 This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > 23-018-10 > Oct > 10 > Body - Lower Door Hinge Popping Groaning Noises > Page 8645 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 8646 Rear Door Hinge: By Symptom Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 8647 SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 8648 TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Technical Service Bulletin # 23-018-10 Date: 101021 Body - Lower Door Hinge Popping Groaning Noises NUMBER: 23-018-10 GROUP: Body DATE: October 21, 2010 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-016-06, DATED MARCH 18, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS. SUBJECT: Lower Door Hinges Make Popping or Groan When Opened Or Closed OVERVIEW: This bulletin involves spraying white lithium grease between the roller and roller pin while avoiding getting grease on the. This needs to be done to all lower door hinges. CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. MODELS: 2009 - 2010 (DS) Ram Truck (1500 Pick Up) 2005 - 2010 (DH) Ram Truck (1500/2500 Pick Up) 2010 (DJ) Ram Truck (2500 Pick Up) 2004 - 2010 (HB) Durango 2007 - 2010 (HG) Aspen 2007 - 2010 (JC) Journey 2007 - 2010 (JS) Avenger/Sebring 2007 - 2010 (KK) Liberty 2007 - 2010 (KA) Nitro 2008 - 2010 (LC) Challenger 2006 - 2010 (LE) Chrysler 300C (International Markets) 2007 - 2010 (LX) 300/Charger/Magnum Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 8649 2007 - 2010 (MK) Compass/Patriot 2005 - 2010 (ND) Dakota 2007 - 2010 (PM) Caliber 2006 - 2010 (WH) Grand Cherokee (International Markets) 2005 - 2010 (WK) Grand Cherokee 2006 - 2010 (WH) Commander (International Markets) 2006 - 2010 (XK) Commander SYMPTOM/CONDITION: The lower door hinges make a moderate to loud popping/groan sound when the door is opened or closed. This is due to the roller axle not being properly maintained with grease. DIAGNOSIS: Open the doors and listen for the popping or groan sound from the lower hinge, if the sound is present perform the Repair Procedure. PARTS REQUIRED: REPAIR PROCEDURE: 1. Open door. 2. With straw installed on the lithium grease spray can (p/n 04318066AB), spray a very small amount of grease between the roller pin and inside roller surface (axle). (Fig. 1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Door Hinge: > Page 8650 CAUTION: Be careful not to spray grease on the outside of the roller or roller cam. If grease is allowed to get on the outside of the roller or roller cam it must be cleaned off using a clean shop towel. Grease left on the outside of the roller and roller cam may also cause a noise. 3. Open and close the door 10 times to work the grease onto the roller axle. 4. Wipe away any excess grease in the sprayed area. 5. Repeat steps 1 through 4 for every door. POLICY: Reimbursable within the provisions of the warranty. TIME ALLOWANCE: FAILURE CODE: Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Door Hinge - Removal Rear Door Hinge: Service and Repair Rear Door Hinge - Removal REMOVAL NOTE: It is not necessary to remove the door to replace the hinges if they are replaced one at a time. NOTE: The welded washers should not be separated from the hinge. If the washers are removed the door may have to be re-adjusted. NOTE: A suitable body sealant should be used when removing or moving the hinges. UPPER HINGE 1. Using a grease pencil or equivalent, mark the position of the hinge on the door and B-pillar. 2. Remove the nuts (2) attaching the hinge to the door (3). 3. Remove the three bolts (6) attaching the hinge (1) to the B-pillar (2) and remove the hinge. LOWER HINGE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Door Hinge - Removal > Page 8653 1. Using a grease pencil or equivalent, mark the position of the hinge on the door and B-pillar. 2. Remove the lower B-pillar trim, See: Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal. 3. Remove the nuts (2) attaching the hinge to the door (3). 4. Remove the two bolts (5) attaching the hinge (4) to the B-pillar (2). 5. From the inside of the vehicle remove the remaining bolt (3) attaching the hinge (4) to the B-pillar (2) and remove the hinge. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Door Hinge - Removal > Page 8654 Rear Door Hinge: Service and Repair Rear Door Hinge - Installation INSTALLATION UPPER HINGE NOTE: A suitable body sealant should be used when removing or moving the hinges. 1. Install the hinge and nuts to the door washers, if there were removed previously (2). Tighten to 28 Nm (21 ft. lbs.). 2. Install the three hinges to B-pillar bolts (6). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Door Hinge - Removal > Page 8655 3. Tighten the bolts to 28 Nm (21 ft. lbs.) using the sequence shown. NOTE: Right hand door shown, left hand door opposite. 4. Adjust the door if needed. See: Adjustments LOWER HINGE NOTE: A suitable body sealant should be used when removing or moving the hinges. 1. Install the hinge (4) and the B-pillar bolts 5 and 3. 2. Tighten the bolts to 28 Nm (21 ft. lbs.) using the sequence shown. NOTE: Right hand door shown, left hand door opposite. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair > Rear Door Hinge - Removal > Page 8656 3. Install the hinge and nuts to the door washers, if there were removed previously (2). Tighten to 28 Nm (21 ft. lbs.). 4. Adjust the door if needed. See: Adjustments 5. Install the lower B-pillar trim. See: Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch - Removal Rear Door Latch: Service and Repair Rear Door Latch - Removal REMOVAL 1. Remove the watershield. See: Rear Door Panel/Service and Repair/Water Shield - Removal. 2. Disconnect the latch actuator rods 3 and 4. 3. Remove the screws (5) and the latch (1). 4. Disconnect the electrical connector (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Rear Door Latch - Removal > Page 8661 Rear Door Latch: Service and Repair Rear Door Latch - Installation INSTALLATION 1. Position the latch (1) into the door and connect the electrical connector (2). 2. Install the latch and the screws (5). 3. Tighten the screws to 10 Nm (7 ft. lbs.). 4. Connect the actuator rods 3 and 4. 5. Install the watershield. See: Rear Door Panel/Service and Repair/Water Shield - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel - Removal Rear Door Panel: Service and Repair Rear Door Trim Panel - Removal REMOVAL 1. Remove the screws 3 and 5. CAUTION: Trim panel is attached to the door using hooks molded into the panel. Do not pull the trim panel straight off or damage to the panel and/or power switch assembly may occur. 2. Lift the trim panel up off the lock rod (2) and attachment hooks and separate the panel from the door slightly. 3. Disconnect the electrical connectors (6). 4. Disconnect the inside handle actuator rod (1). 5. Disconnect the electrical connector and remove the tweeter. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel - Removal > Page 8666 6. Remove the switch panel if necessary. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel - Removal > Page 8667 Rear Door Panel: Service and Repair Rear Door Trim Panel - Installation INSTALLATION 1. Install the switch assembly. 2. Install the tweeter and connect the electrical connector. 3. Position the trim panel (4) and connect the inside handle actuator rod (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel - Removal > Page 8668 4. Connect the electrical connectors (6). 5. Lift the trim panel up and onto the lock rod (2) and attachment hooks. 6. Install the screws 3 and 5. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel - Removal > Page 8669 Rear Door Panel: Service and Repair Water Shield - Removal REMOVAL CAUTION: Do not allow the watershield or adhesive to become contaminated with dirt or other foreign substances. Do not damage the watershield during removal and installation. If the watershield becomes contaminated or damaged, replace the watershield. 1. Remove the speaker. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Speaker - Removal 2. Remove the door trim panel. See: Rear Door Trim Panel - Removal 3. Separate the watershield from the inner door panel and off of the latch linkages. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Rear Door Trim Panel - Removal > Page 8670 Rear Door Panel: Service and Repair Water Shield - Installation INSTALLATION CAUTION: Do not allow the watershield or adhesive to become contaminated with dirt or other foreign substances. Do not damage the watershield during removal and installation. If the watershield becomes contaminated or damaged, replace the watershield. 1. Position the wire harness and actuator rods through the holes in the watershield. 2. Secure the watershield to the inner door panel. 3. Install the speaker. See: Accessories and Optional Equipment/Radio, Stereo, and Compact Disc/Speaker/Service and Repair/Speaker - Installation 4. Install the trim panel. See: Rear Door Trim Panel - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments Rear Door Striker: Adjustments ADJUSTMENT 1. Using a grease pencil or equivalent, mark the position of the striker (2) to aid in adjustment. 2. Loosen the striker bolts (1). 3. Change the striker position to adjust the rear gap and flush measurement. 4. Tighten the bolts to 28 Nm (21 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Service and Repair > Door Latch Striker - Removal Rear Door Striker: Service and Repair Door Latch Striker - Removal REMOVAL 1. Using a grease pencil or equivalent, mark the position of the striker (2). 2. Remove the bolts (1) and remove the striker. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Inner Belt Weatherstrip - Installation Rear Door Weatherstrip: Service and Repair Rear Door Inner Belt Weatherstrip - Installation INSTALLATION 1. Position weatherstrip on inner door panel. 2. Press into place. 3. Install trim panel. See: Rear Door Panel/Service and Repair/Rear Door Trim Panel - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Inner Belt Weatherstrip - Installation > Page 8680 Rear Door Weatherstrip: Service and Repair Rear Door Outer Belt Weatherstrip - Removal REMOVAL 1. Insert special tool #9093 (2) between the outer belt molding (1) and glass at the rear. 2. Push down on outer belt molding (1) and rotate upper part of tool (2) outward from vehicle then lift up on molding (1) to disengage from locking tabs (3) working from back to front. NOTE: Typical outer belt molding design shown. 3. Slide molding out from under the side view mirror and remove. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Inner Belt Weatherstrip - Installation > Page 8681 Rear Door Weatherstrip: Service and Repair Rear Door Outer Belt Weatherstrip - Installation INSTALLATION 1. Position the outer belt molding onto the door and seat the molding fully starting at the back of the door. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Removal REMOVAL 1. Remove the watershield. See: Rear Door Panel/Service and Repair/Water Shield - Removal. 2. Temporarily install the window switch and position the glass (1) to gain access to the regulator nuts (4). 3. Remove the nuts (4). 4. Secure the glass in the up position using a wood wedge or equivalent. 5. Remove the bolts (2) and loosen the remaining regulator bolts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal > Page 8686 6. Separate the regulator (3) from the door panel (1) and disconnect the electrical connector (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal > Page 8687 Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Installation INSTALLATION 1. Position the regulator (3) into the door (1) and connect the electrical connector (2). 2. Position the regulator bolts into the keyhole slots and slide into place. 3. Install the remaining regulator bolts (2). 4. Tighten the bolts to 9 Nm (80 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal > Page 8688 5. Position the glass (1) onto the door regulator (3). 6. Install the nuts (4) and tighten to 9 Nm (80 in. lbs.). 7. Install the watershield. See: Rear Door Panel/Service and Repair/Water Shield Installation 8. Perform the Clear/Relearn procedure. See: Windows and Glass/Windows/Testing and Inspection/Programming and Relearning. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Hood Hinge - Removal Hood Hinge: Service and Repair Hood Hinge - Removal REMOVAL NOTE: It is not necessary to remove the hood to replace one or both hinges. The hinges can be replaced one at a time. 1. Open hood and support the side that requires hinge replacement. 2. Remove the cowl grille. See: Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Cover - Removal 3. Mark all bolt and hinge attachment locations using a grease pencil or equivalent, to provide reference marks for installation. 4. Remove the fender support bolt. 5. Remove the plastic rivets and remove the wheelhouse splash shield. See: Fender/Front Fender/Front Fender Liner/Description and Operation 6. Remove the nuts attaching the hinge to the hood. 7. From inside the fender, remove the two hinge bolts (1). 8. Slide the hinge (2) forward and remove from the fender rail. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Hood Hinge - Removal > Page 8694 Hood Hinge: Service and Repair Hood Hinge - Installation INSTALLATION 1. Install the hinge (2), slide back into position on the fender rail and align all marks. 2. From inside the fender, install the two hinge bolts (1). 3. Tighten the rear bolt to 20 Nm (15 ft. lbs.) 4. Tighten the front bolt to 20 Nm (15 ft. lbs.) 5. Install the nuts attaching the hinge to the hood and tighten the nuts to 23 Nm (17 ft. lbs.) 6. Install the fender support bolt and tighten to 8 Nm (75 in. lbs.). 7. Install the cowl grille. See: Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Cover - Installation 8. Install the wheelhouse splash shield and install the rivets. See: Fender/Front Fender/Front Fender Liner/Description and Operation 9. Check hood fit and adjust if required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Adjustments Hood Latch: Adjustments ADJUSTMENTS 1. Check and adjust the hood if required. See: Adjustments 2. Remove the push pin fasteners and remove the upper radiator shroud. 3. Loosen the hood latch bolts (3). 4. Move the latch to the correct location and lightly tighten the bolts. 5. Close the hood slowly and observe the latching operation. 6. If necessary, adjust the latch position and tighten the bolts to 11 Nm (8 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch - Removal Hood Latch: Service and Repair Hood Latch - Removal REMOVAL 1. Remove the push pin fasteners and remove the upper radiator shroud. 2. Using a grease pencil or equivalent, mark latch position for installation alignment. 3. Remove bolts (3) attaching hood latch (4) to upper radiator crossmember (1). 4. Separate hood latch (1) from crossmember and disconnect the release cable (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch - Removal > Page 8700 Hood Latch: Service and Repair Hood Latch - Installation INSTALLATION 1. Connect release cable (2) to the hood latch (1). 2. Install the latch (4) lining up the marks made previously and install the bolts (3). 3. Tighten the bolts to 11 Nm (8 ft. lbs.). 4. Close hood and adjust latch as necessary. See: Adjustments Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Release Cable - Removal Hood Latch Release Cable: Service and Repair Hood Release Cable - Removal REMOVAL 1. Remove the grille. See: Grille/Service and Repair/Grille - Removal 2. Remove hood latch (4). See: Hood Latch/Service and Repair/Hood Latch - Removal 3. Remove the left headlamp unit, See: Lighting and Horns/Service and Repair/Front Lamp Unit - Removal. 4. Remove the plastic rivets and remove the left front wheelhouse splash shield. See: Fender/Front Fender/Front Fender Liner/Description and Operation 5. Detach the release cable and the retainer clips (2) in the engine compartment. 6. Separate the release cable grommet from the dash panel hole. 7. Detach the release cable and the retainer clips (4). 8. From the inside of the vehicle, remove the screws (5) attaching the hood release handle (2) to the bottom of the instrument panel (1). 9. Pull/route the hood release cable through the dash panel hole and remove it from the inside of the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Hood Release Cable - Removal > Page 8705 Hood Latch Release Cable: Service and Repair Hood Release Cable - Installation INSTALLATION NOTE: If replacement hood latch is also being installed, ensure that it is thoroughly lubricated. 1. From inside the vehicle, pull/route the hood release cable through the dash panel hole and into the engine compartment. 2. Install the hood release handle (2) and install the screws (5). 3. Install the cable grommet in the dash panel hole. 4. Attach the retainer clip (4) to the release cable and install. 5. Attach the retainer clips (2) to the release cable and install them into the holes in the engine compartment. 6. Install hood latch. See: Hood Latch/Service and Repair/Hood Latch - Installation 7. Install the wheelhouse splash shield and install the rivets. See: Fender/Front Fender/Front Fender Liner/Description and Operation 8. Install the left headlamp unit, See: Lighting and Horns/Service and Repair/Front Lamp Unit - Installation. 9. Install the grille. See: Grille/Service and Repair/Grille - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Hood Ajar Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Hood Ajar Switch > Page 8711 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 8712 Hood Sensor/Switch (For Alarm): Diagrams Connector (HEV) - 2 WAY SWITCH-HOOD AJAR 2 (HEV) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in three different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic market vehicles equipped with either an optional remote starter system or the optional Hybrid Electric Vehicle (HEV) system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole. For the vehicle theft and remote start applications, the switch is secured within the stamped metal inner left fender mounting flange within the engine compartment. For the HEV applications, the switch is secured within the stamped metal inner right fender mounting flange within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system or HEV system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description > Page 8715 Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export market vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Front Control Module (FCM). The FCM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic market vehicles only - white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the FCM and the hood ajar switch sense input of the FCM. The FCM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. When the hood switch is closed (hood is open), the remote start feature is disabled. In the Hybrid Electric Vehicle (HEV) system application (white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between ground and the hood ajar switch sense input of the Powertrain Control Module (PCM). The PCM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. When the hood switch is closed (hood is open), the gasoline engine auto-start feature is disabled. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting hole, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the FCM or PCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export market vehicle theft, domestic market remote starter or the HEV systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Removal Striker STRIKER NOTE: Vehicles equipped with two hood ajar switches are also equipped with two strikers. NOTE: The hood ajar switch strikers are not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using hand pressure, slide the hood ajar switch striker (2) toward the large end of the keyed mounting hole (3) in the inner hood panel reinforcement (1) far enough to disengage it. 3. Remove the striker from the inner hood panel reinforcement and discard. Switch SWITCH NOTE: Some vehicles are equipped with two hood ajar switches. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 3. From the top of the left or right front fender inner shield, squeeze the two hood ajar switch latch tabs (1) together and pull the switch upward out of Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal > Page 8718 the mounting hole (2). 4. Pull the hood ajar switch up through the hole far enough to access and disconnect the wire harness connector (3) from the switch connector receptacle. 5. Remove the hood ajar switch from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal > Page 8719 Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Installation Striker STRIKER NOTE: Vehicles equipped with two hood ajar switches are also equipped with two strikers. NOTE: The hood ajar switch striker caps are not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) into the large end of the keyed mounting hole (3) in the inner hood panel reinforcement (1) over the hood ajar switch. 2. Using hand pressure, slide the striker upward into the small end of the mounting hole in the inner hood panel reinforcement until it is fully engaged. 3. Close and latch the hood. Switch SWITCH NOTE: Some vehicles are equipped with two hood ajar switches. 1. Position the hood ajar switch (1) near the mounting hole (2) in the left front fender inner shield. 2. Reconnect the wire harness connector (3) to the switch connector receptacle. 3. Insert the switch into the mounting hole until the integral switch latch tabs lock it into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal > Page 8720 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. 5. Close and latch the hood. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal Liftgate Window Glass: Service and Repair Liftgate Backlite - Removal REMOVAL NOTE: Windshield removal shown, backlite similar. 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Windows and Glass/Windshield/Service Precautions 2. Remove liftgate trim panels. See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal 3. Remove the center stop light. . See: Lighting and Horns/Center Mounted Brake Lamp/Service and Repair/Center Mounted Brake Lamp - Removal 4. Remove rear window wiper arm, if equipped. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 5. Disconnect the heated backlite electrical connectors, if equipped. 6. Using a windshield cut-out wire or other suitable tool, separate the adhesive. 7. Carefully remove backlite. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal > Page 8726 Liftgate Window Glass: Service and Repair Liftgate Backlite - Installation INSTALLATION WARNING: Allow the urethane at least 24 hours to cure before returning the vehicle to use. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing backlite to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. NOTE: The backlite fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Support spacers should be replaced with new parts. Replace any missing or damaged spacers around the perimeter of the liftgate opening. Glass Preparation - Installing A Previously Installed Backlite 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Windows and Glass/Windshield/Service Precautions 2. Level old bead of backlite adhesive (3) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. 3. Apply four new spacers (1) to the liftgate frame and place them 55 mm in from the window opening; 70 mm from the upper edge and 150 mm from the lower edge. 4. Install the lower spacers (2) to the backlite approximately 36 cm (1.0 in) from each side of the glass. NOTE: Remove the lower spacers 2 hours after installation of the glass. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal > Page 8727 5. Position backlite in center of liftgate opening and resting on the side and lower spacers. 6. Apply adhesive tape strips (1) around the perimeter of the liftgate opening to aid in installation. NOTE: Windshield installation shown, backlite similar. 7. Verify the backlite gap is parallel to with the liftgate opening. 8. Cut tape with a sharp knife and remove backlite. NOTE: Typical primer installation shown. 9. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 10. Using a flash light, verify that glass primer is without damage. 11. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal > Page 8728 12. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2). 13. Allow primer to air dry for at least 10 minutes. 14. Using a flash light, verify that glass primer is without damage. Glass Preparation - Installing A New Backlite 1. Apply four new spacers (1) to the liftgate frame and place them 55 mm in from the window opening; 70 mm from the upper edge and 150 mm from the lower edge. 2. Install the lower spacers (2) to the backlite approximately 36 cm (1.0 in) from each side of the glass. NOTE: Remove the lower spacers 2 hours after installation of the glass. 3. Position backlite in center of liftgate opening and resting on the side and lower spacers. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal > Page 8729 4. Apply adhesive tape strips (1) around the perimeter of the liftgate opening to aid in installation. NOTE: Windshield installation shown, backlite similar. 5. Verify the backlite gap is parallel to with the liftgate opening. 6. Cut tape with a sharp knife and remove backlite. NOTE: Typical primer installation shown. 7. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 8. Apply primer to gluing surface at backlite seal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal > Page 8730 9. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2). 10. Allow primer to air dry for at least 10 minutes. 11. Using a flash light, verify that glass primer is without damage. Liftgate Opening Preparation NOTE: Windshield opening shown, liftgate opening similar. 1. Clean and vacuum liftgate opening. 2. Level old bead of liftgate opening adhesive (1) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal > Page 8731 NOTE: Windshield opening shown, liftgate opening similar. 3. Clean and dry area of liftgate opening to be re-glued with a suitable glass preparation solvent and rag. 4. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. 5. Allow primer to air dry for at least 10 minutes. Backlite Installation 1. Apply bead of adhesive (1) with a triangular nozzle directly to the backlite seal starting at bottom in center of the backlite. CAUTION: Always apply bead of adhesive to the backlite. Always install the backlite within 5 minutes after applying adhesive. 2. Bead dimensions should be approximately 9.5 mm wide (1) by 12.7 mm in height (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal > Page 8732 3. Allow end of adhesive bead (1) to run out parallel to the start of the bead and smooth ends flush. 4. Lift backlite into place in the center of the liftgate opening and use the tape as a guide to aid installation of the backlite into the center of the cutout. 5. Carefully lay down the backlite and press on. CAUTION: It is no longer possible to move the backlite after installation. The backlite should never be pressed into place by more than one person, because the backlite can break if pressed simultaneously on both sides. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing backlite to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. 6. Install the rear wiper arm, if equipped. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation 7. Install the liftgate trim panels. 8. Install the center stop light, . See: Lighting and Horns/Center Mounted Brake Lamp/Service and Repair/Center Mounted Brake Lamp Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Locations > Power Liftgate Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Locations > Power Liftgate Module > Page 8737 Power Trunk / Liftgate Control Module: Locations Power Liftgate Module C2 (Body) 22 Way Connector C2 - (BODY) 22 WAY MODULE-POWER LIFTGATE - (BODY) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Locations > Power Liftgate Module > Page 8738 Power Trunk / Liftgate Control Module: Locations Power Liftgate Module C3 (Body) 2 Way Connector C3 - (BODY) 2 WAY MODULE-POWER LIFTGATE - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Diagrams > Power Liftgate Module C1 (Body) 12 Way Power Trunk / Liftgate Control Module: Diagrams Power Liftgate Module C1 (Body) 12 Way Connector C1 - (BODY) 12 WAY MODULE-POWER LIFTGATE - (BODY) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Diagrams > Power Liftgate Module C1 (Body) 12 Way > Page 8741 Power Trunk / Liftgate Control Module: Diagrams Power Liftgate Module C2 (Body) 22 Way Connector C2 - (BODY) 22 WAY MODULE-POWER LIFTGATE - (BODY) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Diagrams > Power Liftgate Module C1 (Body) 12 Way > Page 8742 Power Trunk / Liftgate Control Module: Diagrams Power Liftgate Module C3 (Body) 2 Way Connector C3 - (BODY) 2 WAY MODULE-POWER LIFTGATE - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Description and Operation > Power Liftgate Control Module - Description Power Trunk / Liftgate Control Module: Description and Operation Power Liftgate Control Module Description DESCRIPTION Vehicles equipped with a power liftgate system utilize a power liftgate control module (4). This module is located on the left side of the vehicle behind the C-pillar below the quarter glass The power liftgate control module receives and monitors logic inputs from all the power liftgate system switches. This module also contains the software technology to detect liftgate obstructions and stop or reverse the door accordingly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Description and Operation > Power Liftgate Control Module - Description > Page 8745 Power Trunk / Liftgate Control Module: Description and Operation Power Liftgate Control Module Operation OPERATION The power liftgate control module contains the electronic circuitry and software used to control the sequence of events for the power liftgate system. This module communicates on the Controller Area Network (CAN) to monitor many different inputs and outputs such as door lock status, transmission gear selector position and vehicle speed. The power liftgate open/close command can be initiated by either one press of the power liftgate overhead console switch or two presses of the key fob power liftgate switch. The overhead switch is hardwired to the power liftgate control module. The key fob, sends a signal out on the Controller Area Network (CAN) Data Bus circuit. This signal is detected at the Power Liftgate Control Module. The power liftgate control module then interprets the information to confirm safety requirements are met before applying power to the power liftgate drive unit to start a power cycle. During a power liftgate open or close cycle, if the power liftgate control module detects sufficient resistance to liftgate travel, such as an obstruction in the liftgate's path. The control module will immediately stop liftgate movement and reverse the direction of travel to the full open or closed position. The power liftgate control module has the ability to relearn. After 8 miles have been recorded on the odometer, anytime the liftgate is fully opened and fully closed using the automatic system, the module will learn from its cycle. If a replacement power liftgate component is installed or a liftgate adjustment is made, the module will relearn the effort and time required to open or close the liftgate. This learn cycle can be performed with a Diagnostic Scan Tool or with a complete cycle of the liftgate, using either one of the command switches. See: Testing and Inspection/Programming and Relearning for detailed instructions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Description and Operation > Page 8746 Power Trunk / Liftgate Control Module: Testing and Inspection POWER LIFTGATE CONTROL MODULE Any diagnosis of the Power Liftgate System should begin with the use of a diagnostic scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Procedures Information. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. Before any testing of the power liftgate system is attempted, the battery should be fully-charged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Service and Repair > Power Liftgate Control Module - Removal Power Trunk / Liftgate Control Module: Service and Repair Power Liftgate Control Module Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left quarter trim panel from the vehicle, See: Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the wire harness connectors (2) from the power liftgate control module (4). 4. Using molding remover C-4829A gently pry the clip (1) out of the retaining hole holding the power liftgate control module (4) to the quarter panel. 5. Tilt the top of the module (4) away from the quarter panel and lift upward to disengage the mounting tab from the locating slot (3). 6. Remove the power liftgate control module (4) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Control Module > Component Information > Service and Repair > Power Liftgate Control Module - Removal > Page 8749 Power Trunk / Liftgate Control Module: Service and Repair Power Liftgate Control Module Installation INSTALLATION 1. Position the power liftgate control module (4) into the vehicle. 2. Insert the mounting tab into the locating slot (3) on the quarter panel. 3. Tilt the top of the module (4) toward the quarter panel and firmly press the clip (1) into the retaining hole on the quarter panel. 4. Connect the wire harness connectors (2) to the power liftgate control module (4). 5. Install the left quarter trim panel, See: Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel Installation. 6. Connect the battery negative cable. 7. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes. 8. Perform the power liftgate learn cycle, See: Testing and Inspection/Programming and Relearning. 9. Verify power liftgate system operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Manual Release Liftgate Latch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Locations > Manual Release Liftgate Latch > Page 8754 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams > Manual Release Liftgate Latch (Liftgate) 3 Way Power Trunk / Liftgate Lock Actuator: Diagrams Manual Release Liftgate Latch (Liftgate) 3 Way Connector - (LIFTGATE) 3 WAY LATCH-LIFTGATE-MANUAL RELEASE - (LIFTGATE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams > Manual Release Liftgate Latch (Liftgate) 3 Way > Page 8757 Power Trunk / Liftgate Lock Actuator: Diagrams Power Liftgate Latch (Liftgate) 8 Way Connector - (LIFTGATE) 8 WAY LATCH-POWER LIFTGATE - (LIFTGATE) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations > Left Liftgate Pinch Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations > Left Liftgate Pinch Sensor > Page 8762 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Diagrams > Left Liftgate Pinch Sensor (Power Liftgate) (Liftgate) 2 Way Power Trunk / Liftgate Hazard Sensor: Diagrams Left Liftgate Pinch Sensor (Power Liftgate) (Liftgate) 2 Way Connector (POWER LIFTGATE) - (LIFTGATE) 2 WAY SENSOR-LIFTGATE PINCH-LEFT (POWER LIFTGATE) - (LIFTGATE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Diagrams > Left Liftgate Pinch Sensor (Power Liftgate) (Liftgate) 2 Way > Page 8765 Power Trunk / Liftgate Hazard Sensor: Diagrams Right Liftgate Pinch/Temperature Sensor (Power Liftgate) (Liftgate) 2 Way Connector (POWER LIFTGATE) - (LIFTGATE) 2 WAY SENSOR-LIFTGATE PINCH/TEMP-RIGHT (POWER LIFTGATE) - (LIFTGATE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Description and Operation > Pinch Sensor - Description Power Trunk / Liftgate Hazard Sensor: Description and Operation Pinch Sensor - Description DESCRIPTION Pinch sensors (2) are located on each side of the liftgate (1). These sensors look like weather-strips, however they consist of pieces of electrically conductive rubber (tapeswitch), wires, resistor, double sided tape, and a plastic carrier. They are used to indicate an obstruction during a power liftgate close cycle. The right side pinch sensor contains a thermistor that is integral to the pinch sensor assembly. The thermistor is a temperature sensor used by the power liftgate control module to enable proper liftgate operation in extreme climate conditions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Description and Operation > Pinch Sensor - Description > Page 8768 Power Trunk / Liftgate Hazard Sensor: Description and Operation Pinch Sensor - Operation OPERATION During a power liftgate "close" cycle, if either of the two conductive rubber strips (tapeswitch) of the pinch sensor come in contact with an obstacle, the pinch sensor circuit is completed. This tells the power liftgate control module that a obstruction is felt. The control module will stop the liftgate immediately and return it to the full open position. The thermistor portion of the right pinch sensor provides the temperature signal to the power liftgate control module (temperature is provided when the pinch sensor is in an unpinched condition; when pinched, temperature is unavailable because the thermistor is shorted). As the outside temperature increases, the resistance reading decreases. As temperature decreases, the resistance reading increases. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Description and Operation > Page 8769 Power Trunk / Liftgate Hazard Sensor: Testing and Inspection RIGHT PINCH SENSOR/THERMISTOR The thermistor portion of the right pinch sensor provides the temperature signal to the power liftgate control module (temperature is provided when the pinch sensor is in an unpinched condition; when pinched, temperature is unavailable because the thermistor is shorted). Refer to the RIGHT PINCH SENSOR/THERMISTOR DIAGNOSTIC TABLE to test the thermistor resistance. RIGHT PINCH SENSOR/THERMISTOR DIAGNOSTIC TABLE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Service and Repair > Pinch Sensor - Removal Power Trunk / Liftgate Hazard Sensor: Service and Repair Pinch Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove trim panel from liftgate, See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal. 3. Disconnect the pinch sensor wire harness connector (4). 4. Remove the clips/assembly holding the pinch sensor (2) to liftgate (1). 5. Feed the pinch sensor wire harness (5) out of the liftgate (1) and remove the sensor (2) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Sensor > Component Information > Service and Repair > Pinch Sensor - Removal > Page 8772 Power Trunk / Liftgate Hazard Sensor: Service and Repair Pinch Sensor - Installation INSTALLATION WARNING: Use extreme caution when testing pinch sensor operation. 1. Route the pinch sensor wire harness (5) through the hole in the liftgate (1). Push the wire harness grommet into place until fully seated. 2. Position the pinch sensor (2) to the liftgate (1) and align the holes to the fastening clips. 3. Install the four clips holding the sensor to the liftgate. 4. Connect the pinch sensor wire harness connector (4). 5. Install the trim panel on the liftgate, See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Installation. 6. Connect the battery negative cable. 7. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes related to the pinch sensor. 8. Verify power liftgate system and pinch sensor operation. Cycle the power liftgate through one complete open and close cycle, during the final close cycle press the pinch sensor to verify the power liftgate detects an obstruction and returns to the full open position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Tone Speaker > Component Information > Locations > Power Liftgate Chime (1) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Tone Speaker > Component Information > Locations > Power Liftgate Chime (1) > Page 8777 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Hazard Tone Speaker > Component Information > Locations > Page 8778 Power Trunk / Liftgate Hazard Tone Speaker: Diagrams Connector - (LIFTGATE) 2 WAY CHIME-POWER LIFTGATE - (LIFTGATE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch > Component Information > Locations > Page 8782 Trunk / Liftgate Ajar Switch: Diagrams Connector - (LIFTGATE) 2 WAY SWITCH-LIFTGATE AJAR - (LIFTGATE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch > Component Information > Description and Operation > Liftgate Ajar Switch - Description Trunk / Liftgate Ajar Switch: Description and Operation Liftgate Ajar Switch - Description LIFTGATE A liftgate ajar switch is standard equipment on this vehicle. The switch is concealed within and integral to the liftgate latch unit. The switch is a momentary leaf contact-type unit that is actuated by the liftgate latch mechanisms. An integral connector receptacle on the liftgate latch connects the liftgate ajar switch to the vehicle electrical system through the liftgate wire harness. The liftgate ajar switch cannot be adjusted or repaired and, if ineffective or damaged, the liftgate latch unit must be replaced. See: Trunk / Liftgate Latch/Service and Repair/Removal and Replacement/Latch - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch > Component Information > Description and Operation > Liftgate Ajar Switch - Description > Page 8785 Trunk / Liftgate Ajar Switch: Description and Operation Liftgate Ajar Switch - Operation LIFTGATE The liftgate ajar switch is actuated by the liftgate latch mechanism. When the liftgate is closed and properly latched, its liftgate ajar switch is an open circuit. When the liftgate is open or only partially latched, the liftgate ajar switch is a closed circuit. The liftgate ajar switch is hard wired in series between a body ground and the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC reads the hard wired liftgate ajar switch input through an internal pull-up, then uses this input to control many electronic functions and features of the vehicle. The liftgate ajar switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Hinge - Removal Trunk / Liftgate Hinge: Service and Repair Hinge - Removal REMOVAL NOTE: It is not necessary to remove the liftgate to replace one or both hinges. The hinges can be replaced one at a time. NOTE: A suitable body sealant should be used when removing or moving the hinges. 1. Support liftgate on a suitable lifting device. 2. Using a trim stick C-4755 or equivalent, remove the upper rear headliner trim. 3. Using a grease pencil or equivalent, mark the location of the hinge to aid installation. 4. Remove the liftgate bolts (2). 5. Remove the body bolts (1) and remove the hinge. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Hinge - Removal > Page 8790 Trunk / Liftgate Hinge: Service and Repair Hinge - Installation INSTALLATION NOTE: A suitable body sealant should be used when removing or moving the hinges. 1. If necessary, paint replacement hinge before installation. 2. Install the hinge (2) and install the body bolts (1). 3. Tighten the bolts to 28 Nm (21 ft. lbs.). 4. Install the liftgate bolts (2) and tighten to 28 Nm (21 ft. lbs.). 5. Adjust liftgate if necessary. See: Adjustments/Liftgate - Adjustments 6. Position the upper rear headliner trim and seat fully. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Exterior Handle - Removal Trunk / Liftgate Handle: Service and Repair Exterior Handle - Removal REMOVAL 1. Remove the trim panels. See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal 2. Disconnect the latch actuator rod (2). 3. Remove the screws (3) and from the inside of the liftgate, squeeze the arrowheads of the four clips 2 and 4 to push them through the sheetmetal, then remove the handle (5). 4. Remove the lamp by turning the lamp socket a half-turn and removing it from the handle (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle > Component Information > Service and Repair > Exterior Handle - Removal > Page 8795 Trunk / Liftgate Handle: Service and Repair Exterior Handle - Installation INSTALLATION 1. Install the lamp socket into the lamp housing in the handle and turn it a half turn. 2. Install the handle to the liftgate and snap home the four clips 2 and 4 beginning with the middle two then the outer two. 3. Install the screws (3). 4. Insert the bent end of the latch actuator rod (2) to the swing clip on the latch (4), and snap clip onto rod. Then without changing the position of the liftgate outside handle (1), snap the grooved end of the rod into the metal clip on the handle. 5. Install the trim panels, See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel - Removal Trunk / Liftgate Interior Trim Panel: Service and Repair Liftgate Trim Panel - Removal REMOVAL 1. Using a trim stick C-4829A or equivalent, separate the pushpin fasteners and remove the upper trim panel (2). 2. Remove the two upper screws (3) and the four lower screws (5). 3. Remove the lower trim panel (4) and disconnect the electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Interior Trim Panel > Component Information > Service and Repair > Liftgate Trim Panel - Removal > Page 8800 Trunk / Liftgate Interior Trim Panel: Service and Repair Liftgate Trim Panel - Installation INSTALLATION 1. Connect the electrical connector and install the lower trim panel (4) onto the guide pins (2). 2. Install the four lower screws (5) and two upper screws (3). 3. Position the upper trim (2) into place and seat the push pin fasteners fully. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Description and Operation > Power Liftgate Latch - Description Trunk / Liftgate Latch: Description and Operation Power Liftgate Latch - Description DESCRIPTION Vehicles equipped with a power liftgate, utilize a power cinch/release latch. This power liftgate latch performs the same function as a manual liftgate latch as well as the power cinch/release capability. The power cinch/release latch function is made possible by a latch actuator attached to the top of the liftgate latch assembly. This latch actuator contains a small drive gear that meshes with the latch assemblies internal gears to perform the power cinch/release function. The latch actuator is controlled by the power liftgate control module, which controls the cinch function and limits actuator current draw to protect the assembly. The latch is located in the lower center of the liftgate assembly and contains integral switches. These switches include, liftgate ajar, secondary, pawl, sector and power liftgate exterior handle. The power latch cannot be adjusted or repaired and if damaged or inoperative must be replaced. See: Service and Repair/Removal and Replacement/Power Liftgate Latch - Removal for the appropriate procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Description and Operation > Power Liftgate Latch - Description > Page 8805 Trunk / Liftgate Latch: Description and Operation Power Liftgate Latch - Operation OPERATION NOTE: Power latch "Cinching" will become disabled if the pinch sensors are inoperable or damaged. Operating on hardwired inputs from the power liftgate control module, the power liftgate latch mounted actuator (cinch/release motor) provides the torque required to close the liftgate from the secondary to the primary closed and latched position. The actuator also releases the liftgate from the primary closed and latched position to the fully unlatched and movable position. Following every cinch or release sequence, the power liftgate latch will return to a "home" or neutral position. If for some reason the latch is unable to return to the "home" position, the power liftgate control module will recognize this and prevent the latch from releasing. If this condition exists, activation of the power liftgate feature or exterior handle will result in a short beep from the power liftgate chime. In this situation, perform the Power Liftgate Latch Homing Procedure, See: Testing and Inspection/Programming and Relearning. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Procedures Trunk / Liftgate Latch: Procedures STANDARD PROCEDURE Power Liftgate 1. To manually open a power liftgate, See: Testing and Inspection/Programming and Relearning. NOTE: The liftgate may be opened manually by raising the latch release lever in the event the liftgate latch assembly becomes inoperative. 2. Remove the access door from the middle of the lower liftgate trim panel. 3. Reaching around to the back of the latch assembly (1), raise the latch release lever (2). Manual Liftgate NOTE: The liftgate may be opened manually by raising the latch release lever (2) in the event the liftgate latch assembly becomes inoperative. 1. Remove the access door from the middle of the lower liftgate trim panel. 2. Reaching around to the back of the latch assembly (1), raise the latch release lever (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Procedures > Page 8808 Trunk / Liftgate Latch: Removal and Replacement Power Liftgate Latch - Removal REMOVAL 1. Remove liftgate trim panels. See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal 2. Remove the grooved end of the latch actuator rod (1) from the metal clip on the exterior handle (4). 3. Disconnect the bent end of the latch actuator rod (2) from the swing clip on the latch (3). 4. Disconnect the electrical connector (1). 5. Remove the screws (3) and remove the latch (2). Power Liftgate Latch - Installation INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Procedures > Page 8809 1. Position the latch (2) into the liftgate and install the screws (3). 2. Tighten the screws to 11 Nm (95 in. lbs.). 3. Connect the electrical connector (1). 4. Insert the bent end of the latch actuator rod (2) to the swing clip on the latch (3), and snap clip onto rod. 5. Without changing the position of the liftgate outside handle, snap the grooved end of the rod (1) into the metal clip on the handle (4). 6. Install the trim panels. See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Installation Latch - Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Procedures > Page 8810 1. Remove liftgate trim panels. See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal 2. Disconnect the exterior handle actuator rod (2). 3. Disconnect the electrical connectors (1). 4. Remove the screws (3) and remove the latch (2). Latch - Installation INSTALLATION 1. Position the latch (2) into the liftgate and install the screws (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair > Procedures > Page 8811 2. Tighten the screws to 11 Nm (95 in. lbs.). 3. Connect the electrical connectors (1). 4. Insert the bent end of the latch actuator rod (2) to the swing clip on the latch (4), and snap clip onto rod. Then without changing the position of the liftgate outside handle (1), snap the grooved end of the rod into the metal clip on the handle. 5. Install the trim panels. See: Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Locations > Page 8815 Trunk / Liftgate Motor: Diagrams Connector - (BODY) 10 WAY ASSEMBLY-POWER LIFTGATE DRIVE UNIT - (BODY) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Description and Operation > Power Liftgate Drive Unit - Description Trunk / Liftgate Motor: Description and Operation Power Liftgate Drive Unit - Description DESCRIPTION Vehicles equipped with a power liftgate system, utilize a power liftgate drive unit (3). The drive unit assembly consists of a DC motor, gear position sensor, clutch, full-open switch, housing/bracket assembly and wire harness. The clutch and motor portion of the assembly provides the power and torque required to open or close the liftgate (5) under most conditions. The Hall Effect position sensor is used to provide the liftgate control module with a clutch/motor speed signal. This speed signal is used to monitor any resistance of liftgate travel and allows the liftgate control module to detect obstructions and control the liftgate accordingly. The clutch assembly is used to allow automatic power open/close mode and full manual operation, if desired. The full-open switch is used to let the liftgate control module know when the liftgate is approaching the full open position. The drive unit (3) is secured to the D-pillar (1) with three retaining bolts (4). The drive unit (3) is connected the liftgate (5) with the link rod (6). The drive unit cannot be adjusted or repaired and if damaged or inoperative must be replaced. See: Service and Repair/Power Liftgate Drive Unit - Removal for the appropriate procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Description and Operation > Power Liftgate Drive Unit - Description > Page 8818 Trunk / Liftgate Motor: Description and Operation Power Liftgate Drive Unit - Operation OPERATION LIFTGATE IS CLOSED The power liftgate open command can be initiated by either one press of the power liftgate overhead console switch or two presses of the key fob power liftgate button. The overhead console switch is hardwired to the power liftgate control module, where as the key fob signal is sent out on the Controller Area Network (CAN) Data Bus circuit. This signal is detected by the power liftgate control module. The power liftgate control module then interprets the information to confirm safety requirements are met. The control module will then signal the liftgate mounted latch assembly to release the liftgate from its primary closed and latched position to the ajar and movable position. The power liftgate drive unit then takes over to move the liftgate into the full open position. LIFTGATE IS OPEN The power liftgate close command can be initiated by either one press of the power liftgate overhead console switch or two presses of the key fob power liftgate button. The overhead console switch is hardwired to the power liftgate control module, where as the key fob signal is sent out on the Controller Area Network (CAN) Data Bus circuit. This signal is detected by the power liftgate control module. The power liftgate control module then interprets the information to confirm safety requirements are met. The control module will then signal the power liftgate drive unit to move the liftgate into the closed position. Once the liftgate mounted latch reaches the body mounted striker assembly, the power latch takes over to cinch the liftgate to the fully closed and latched position. If a obstacle is encountered during a power open or close cycle, the power liftgate control module will automatically reverse direction of the liftgate to prevent vehicle damage or personal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Description and Operation > Power Liftgate Drive Unit - Description > Page 8819 Trunk / Liftgate Motor: Description and Operation Power Liftgate Link Rod - Description DESCRIPTION WARNING: Never attempt to operate the power liftgate system when the link rod is removed or disconnected. Damage to the power liftgate system will result. Vehicles equipped with a power liftgate utilize a link rod (2) assembly. This link rod is located in the left rear of the vehicle and is visible without removing the D-pillar trim. The link rod attaches to the liftgate ball stud (1) at one end and the power liftgate drive unit assembly (3) at the other. The link rod consists of a steel shaft, equipped with a ball socket receptacle at each end. The weight of the liftgate is not supported by the link rod, the liftgate prop rods are designed to support the liftgate. The link rod cannot be adjusted or repaired and if inoperative, must be replaced. See: Service and Repair/Power Liftgate Link Rod - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Description and Operation > Power Liftgate Drive Unit - Description > Page 8820 Trunk / Liftgate Motor: Description and Operation Power Liftgate Link Rod - Operation OPERATION One end of the link rod assembly is attached to the liftgate ball stud, the other end is attached to the power liftgate drive unit. When the drive unit is driven by the liftgate motor assembly the liftgate is moved to the open or closed position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair > Power Liftgate Drive Unit - Removal Trunk / Liftgate Motor: Service and Repair Power Liftgate Drive Unit - Removal REMOVAL WARNING: Never attempt to operate the power liftgate system when the link rod is removed or disconnected. Damage to the power liftgate system will result. 1. Open the liftgate. 2. Disconnect and isolate the battery negative cable. 3. Remove the link rod assembly (6) from the liftgate attachment point (7), See: Power Liftgate Link Rod - Removal. 4. Remove the left rear D-pillar (1) trim panel from the vehicle, See: Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Removal. 5. Disconnect the wire harness connector (2) from the power liftgate drive unit assembly (3). 6. Remove the drive unit retaining bolt closest to the quarter window. 7. Loosen the remaining drive unit assembly retaining bolts (4). 8. Unhook the drive unit assembly (3) from the D-pillar (1) and remove the unit from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair > Power Liftgate Drive Unit - Removal > Page 8823 Trunk / Liftgate Motor: Service and Repair Power Liftgate Drive Unit - Installation INSTALLATION WARNING: Never attempt to operate the power liftgate system when the link rod is removed or disconnected. Damage to the power liftgate system will result. 1. Install the power liftgate drive unit assembly (3) onto the D-pillar (1). 2. Install the drive unit retaining bolts (4). Torque the bolts to 39 Nm (28.5 ft. lbs.). 3. Connect the wire harness connector (2) to drive unit assembly (3). 4. Install the left rear D-pillar (1) trim panel on the vehicle, See: Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Installation. 5. Install the link rod assembly (6) onto the liftgate attachment point (7). See: Power Liftgate Link Rod - Installation for the appropriate procedure. 6. Connect the battery negative cable. 7. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes. 8. Perform the power liftgate learn cycle, See: Testing and Inspection/Programming and Relearning. 9. Verify power liftgate system operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair > Power Liftgate Drive Unit - Removal > Page 8824 Trunk / Liftgate Motor: Service and Repair Power Liftgate Link Rod - Removal REMOVAL CAUTION: Lift the clips (1) only enough to release the link rod (2) from the ball stud (3). WARNING: Never attempt to operate the power liftgate system when the link rod is removed or disconnected. Damage to the power liftgate system will result. 1. Open the liftgate. 2. Using a small flat bladed tool (3), or equivalent, release the retaining clip (2) while pulling the ball socket (1) away from the ball stud (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair > Power Liftgate Drive Unit - Removal > Page 8825 3. Remove the link rod (2) from the liftgate ball stud (1). 4. NOTE: In the event the liftgate ball stud becomes worn or damaged it may be replaced. Refer to the following procedure for ball stud replacement. Using the appropriate sized socket, remove the ball stud (2) from the liftgate (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair > Power Liftgate Drive Unit - Removal > Page 8826 Trunk / Liftgate Motor: Service and Repair Power Liftgate Link Rod - Installation INSTALLATION NOTE: In the event the liftgate ball stud becomes worn or damaged it may be replaced. Refer to the following procedure for ball stud installation. 1. Position the ball stud (2) onto the liftgate (1) and install in mounting hole. Tighten ball stud to 28 Nm (20.5 ft. lbs.). WARNING: Never attempt to operate the power liftgate system when the link rod is removed or disconnected. Damage to the power liftgate system will result. CAUTION: Make sure the retaining clips (1) are seated into the ball socket (2) fully when installed on the liftgate ball stud (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Service and Repair > Power Liftgate Drive Unit - Removal > Page 8827 2. Install the link rod (2) over the ball stud (1) ensuring the retaining clip snaps fully into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Gas Prop - Removal Trunk / Liftgate Shock / Support: Service and Repair Gas Prop - Removal REMOVAL WARNING: Do not remove the liftgate support rods with the liftgate closed. The support rod pistons are operated by high pressure gas and could cause personal injury and/or vehicle damage if they are removed with the pistons compressed (liftgate closed). Once removed, do not attempt to disassemble or repair the support rods. 1. Open the liftgate and support. 2. Using a small flat bladed tool (3), or equivalent, release the retaining clips (2) while pulling the ball socket (1) away from the ball stud (4). NOTE: Lift the clips (1) only enough to release the ball studs (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Gas Prop - Removal > Page 8832 3. Remove the support cylinder (2) from the upper (1) and lower (3) ball studs. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Gas Prop - Removal > Page 8833 Trunk / Liftgate Shock / Support: Service and Repair Gas Prop - Installation INSTALLATION WARNING: Do not remove the liftgate support rods with the liftgate closed. The support rod pistons are operated by high pressure gas and could cause personal injury and/or vehicle damage if they are removed with the pistons compressed (liftgate closed). Once removed, do not attempt to disassemble or repair the support rods. 1. Make sure the retaining clips (1) are seated into the ball socket (2) fully. 2. Install the support cylinder (2) over the ball studs 1 and 3 with the thin end connected to the body and the retaining clips snapping into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Adjustments Trunk / Liftgate Striker: Adjustments ADJUSTMENT 1. Using a grease pencil or equivalent, mark the position of the striker (2) to aid in adjustment. 2. Loosen the striker bolts (1). 3. Change the striker position to adjust the lower liftgate gap and flush measurement. 4. Tighten the bolts to 28 Nm (21 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair > Striker - Removal Trunk / Liftgate Striker: Service and Repair Striker - Removal REMOVAL 1. Remove screws attaching liftgate striker to floor pan (1) and remove the striker. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Power Liftgate Release Switch (Except Sunroof) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Power Liftgate Release Switch (Except Sunroof) > Page 8843 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Power Liftgate Release Switch (Headliner) 4 Way Trunk / Liftgate Switch: Diagrams Power Liftgate Release Switch (Headliner) 4 Way Connector - (HEADLINER) 4 WAY SWITCH-LIFTGATE RELEASE PLG - (HEADLINER) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Power Liftgate Release Switch (Headliner) 4 Way > Page 8846 Trunk / Liftgate Switch: Diagrams Sunroof/Power Liftgate Switch (Headliner) 6 Way Connector - (HEADLINER) 6 WAY SWITCH-SUNROOF/LIFTGATE PLG - (HEADLINER) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch - Installation Trunk / Liftgate Switch: Description and Operation Exterior Handle Switch - Installation DESCRIPTION All vehicles are equipped with a power liftgate exterior handle switch. The switch is integral to the power liftgate latch assembly. It is activated by the exterior handle, located in the license plate light bar, through a mechanical link rod attaching the two together. The power liftgate exterior handle switch is primarily used for manual opening of the liftgate. Activation of the switch during a automatic power "close" cycle will cause the liftgate to reverse direction. Activation of the switch during a power "open" cycle will cause the power liftgate to disengage, allowing full manual operation. The exterior handle cannot be adjusted or repaired and if damaged it must be replaced. See: Trunk / Liftgate Handle/Service and Repair/Exterior Handle - Removal. The power liftgate exterior handle switch cannot be adjusted or repaired and if damaged or inoperative the complete power liftgate latch assembly must be replaced. See: Trunk / Liftgate Latch/Service and Repair/Removal and Replacement/Power Liftgate Latch - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch - Installation > Page 8849 Trunk / Liftgate Switch: Description and Operation Exterior Handle Switch - Removal OPERATION When the exterior liftgate handle is pulled, a mechanical linkage inside the liftgate depresses the power liftgate exterior handle switch in the power liftgate latch assembly. A hard-wired signal is then detected by the Power Liftgate Control Module. The power liftgate control module then looks at the vehicle lock status on the Controller Area Network (CAN) data bus. If the vehicle is not locked and the operating conditions are met, the power liftgate control module then applies power to the latch mounted motor, which moves the liftgate from the primary closed and latched position to the open and movable position. If the liftgate is not pulled open within seven seconds, once the latch releases, the latch will automatically cinch closed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch - Installation > Page 8850 Trunk / Liftgate Switch: Description and Operation Overhead Console Switch - Description DESCRIPTION NOTE: The overhead console shown contains a combination power liftgate/power sunroof switch. Vehicles equipped with the power liftgate and no sunroof contain a single power liftgate switch only. NOTE: On vehicles equipped with both a power sunroof and power liftgate the overhead console switches are serviced together as one assembly. NOTE: Durango overhead console with Electronic Vehicle Information Center (EVIC) shown. Aspen overhead console similar. The power liftgate switch (3) is mounted in the overhead console assembly (1) between the reading lamps (2). The switch is snapped into mounting slots in the overhead console assembly. The momentary, push button-type power liftgate switch, provides a hardwired signal to the Power Liftgate Control Module. If the switch is inoperative or damaged the power liftgate/power sunroof switch assembly must be replaced. See: Service and Repair/Overhead Console Switch - Removal for the appropriate procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch - Installation > Page 8851 Trunk / Liftgate Switch: Description and Operation Overhead Console Switch - Operation OPERATION Battery voltage is supplied to the power liftgate system through a fuse, located in the Integrated Power Module (IPM) assembly. When the power liftgate switch is pushed, a hardwired signal is sent to the Power Liftgate Control Module. The power liftgate control module then interprets the information to confirm safety requirements are met before applying power to the power liftgate drive unit to start a power cycle. During a power liftgate open or close cycle, if the power liftgate control module detects sufficient resistance to liftgate travel, such as an obstruction in the liftgate's path. The control module will immediately stop liftgate movement and reverse the direction of travel to the full open or closed position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Description and Operation > Page 8852 Trunk / Liftgate Switch: Testing and Inspection OVERHEAD CONSOLE LIFTGATE SWITCH Diagnostic resistors are present inside the overhead console liftgate switch. These resistors are used by the power liftgate control module to determine if the switch is stuck, disconnected, shorted or otherwise damaged. Refer to the OVERHEAD CONSOLE LIFTGATE SWITCH DIAGNOSTIC TABLE to test the switch resistance. OVERHEAD CONSOLE LIFTGATE SWITCH DIAGNOSTIC TABLE NOTE: Test table readings are ± 2%. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Service and Repair > Overhead Console Switch - Removal Trunk / Liftgate Switch: Service and Repair Overhead Console Switch - Removal REMOVAL DURANGO 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console assembly (3), See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Using trim stick C-4755 or equivalent, pry the back edge of the power liftgate switch (1) up until the two retaining tabs (2) are fully released. 4. Tilt the power liftgate switch (1) up away from the overhead console assembly (3) until the mounting tab on the opposite side of the switch releases. 5. Remove the switch from the vehicle. ASPEN 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console assembly (3), See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Using trim stick C-4755 or equivalent, pry the side edges (4) of the overhead console assembly out until the two retaining tabs on the power liftgate switch (5) are fully released. 4. Push the switch (5) out through the back of the overhead console (3). 5. Remove the switch from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Service and Repair > Overhead Console Switch - Removal > Page 8855 Trunk / Liftgate Switch: Service and Repair Overhead Console Switch - Installation INSTALLATION DURANGO 1. Position the power liftgate switch into the overhead console assembly so that the large retaining tab (2) is aligned with the large slot between the reading lamps. 2. Gently press the power liftgate switch (1) into the overhead console assembly (3) until the two small mounting tabs (2) have snapped securely into place. 3. Install the overhead console assembly (3), See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Installation. 4. Connect the battery negative cable. 5. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes. 6. Verify power liftgate system operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. ASPEN Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Service and Repair > Overhead Console Switch - Removal > Page 8856 1. Position the power liftgate switch (5) into the overhead console assembly (3). 2. Gently press the power liftgate switch (5) into the overhead console assembly (3) until the mounting tabs have snapped securely into place (4). 3. Install the overhead console assembly (3), See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Installation. 4. Connect the battery negative cable. 5. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes. 6. Verify power liftgate system operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Nameplate - Removal Body Emblem: Service and Repair Nameplate - Removal REMOVAL NOTE: Exterior nameplates are attached to body panels with adhesive tape. 1. Apply a length of masking tape on the body, parallel to the top edge of the nameplate to use as a guide, if necessary. 2. If temperature is below 21°C (70°F) warm emblem with a heat lamp or gun. Do not exceed 52°C (120°F) when heating emblem. 3. Insert a plastic trim stick or a hard wood wedge behind the emblem to separate the adhesive backing from the body. 4. Clean adhesive residue from body with MOPAR(R) Super Kleen solvent or equivalent. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Nameplate - Removal > Page 8862 Body Emblem: Service and Repair Nameplate - Installation INSTALLATION 1. Remove carrier from adhesive tape on back of emblem. 2. Position emblem properly on body. 3. Press emblem firmly to body with palm of hand. 4. If temperature is below 21°C (70°F) warm emblem with a heat lamp or gun to assure adhesion. Do not exceed 52°C (120°F) when heating emblem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Cover - Removal Cowl Moulding / Trim: Service and Repair Cowl Panel Cover - Removal REMOVAL 1. Open the hood and remove the wiper arm nuts (3) and wiper arms (2). See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 2. Remove the two rear screws (1) and the five front push pins (5). 3. Remove the cowl grille (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Description and Operation Front Fender Liner: Description and Operation DESCRIPTION FRONT FENDER LINER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Description and Operation Rear Fender Liner: Description and Operation DESCRIPTION QUARTER-PANEL-LINER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Isolator - Removal Body / Frame Mount Bushing: Service and Repair Body Isolator - Removal REMOVAL 1. Remove all cab to frame mounting bolts (3) and rebound cushions (2). 2. Remove the front end sheet metal mounting bolt (2). 3. Using a floor jack and block of wood under the cab sill, lift the body to gain access to the isolators. 4. Remove the cab isolators (1) and the front end sheet metal mounting isolator (3). 5. Install new isolators and repeat Steps 1 through 4, for the opposite side. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Body Isolator - Removal > Page 8881 Body / Frame Mount Bushing: Service and Repair Body Isolator - Installation INSTALLATION CAUTION: Whenever a body isolator bolt requires servicing or tightening, it is necessary to remove the bolt and install new thread locker compound to the threads. 1. Install the isolators (1) rebound cushions (2), and bolts (3). 2. Install the front end sheet metal mounting isolators 1 and 3 and install the bolt (2). 3. Tighten the bolts to 81 Nm (60 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal Cross-Member: Service and Repair Crossmember - Removal REMOVAL 1. Raise and support the vehicle. 2. Remove the bolts (1) and nuts (3) and remove the crossmember (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Crossmember - Removal > Page 8886 Cross-Member: Service and Repair Crossmember - Installation INSTALLATION 1. Install the crossmember (2). 2. Install the bolts (1) and nuts (3). 3. Tighten the bolts and nuts to 102 Nm (75 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Skid Plate - Removal Skid Plate: Service and Repair Skid Plate - Removal Transfer Case REMOVAL 1. Remove the bolts (1) and remove the skid plate (2). Fuel Tank REMOVAL 1. Raise and support the vehicle. 2. Support the skid plate with a suitable lifting device. 3. Remove inboard bolts (4). 4. Remove bolts (3) that attach skid plate to frame side rail and remove the skid plate. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Skid Plate > Component Information > Service and Repair > Skid Plate - Removal > Page 8891 Skid Plate: Service and Repair Skid Plate - Installation Transfer Case INSTALLATION 1. Position the skid plate (2) on the vehicle. 2. Install the bolts (1) and tighten to 23 Nm (17 ft. lbs.). Fuel Tank INSTALLATION 1. Position and support skid plate under fuel tank. 2. Install inboard bolts and tighten to 41 Nm (30 ft. lbs.). 3. Install bolts attaching skid plate to frame side rail and tighten to 37 Nm (27 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch - Removal Trailer Hitch: Service and Repair Trailer Hitch - Removal REMOVAL 1. Remove the rear bumper. See: Bumper/Rear Bumper/Rear Bumper Reinforcement/Service and Repair/Rear Bumper Support - Removal. 2. Remove the rear cab to frame bolts (3) and rebound cushions (2) to remove the front hitch bolt. 3. Support trailer hitch on a suitable lifting device. 4. Disconnect the trailer electrical wiring electrical connector. 5. Remove the bolts (3 and 5) and nuts (2) attaching trailer hitch (4) to frame rails (1). 6. Separate trailer hitch (4) from vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Hitch > Component Information > Service and Repair > Trailer Hitch - Removal > Page 8896 Trailer Hitch: Service and Repair Trailer Hitch - Installation INSTALLATION 1. Position trailer hitch on vehicle. 2. Install the bolts and nuts (2, 3 and 5) attaching trailer hitch to frame rail and tighten to 183 Nm (135 ft. lbs.). 3. Connect the trailer wiring electrical connector. 4. Install the rear body rebound cushions (2) and cab mounting bolts (3) and tighten to 81 Nm (60 ft. lbs.). 5. Install the rear bumper. See: Bumper/Rear Bumper/Rear Bumper Reinforcement/Service and Repair/Rear Bumper Support - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Locations Trailer Towing Relay: Locations Trailer Tow Left and Right Relays are located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Diagrams > Relay-Trailer Tow-Left Trailer Towing Relay: Diagrams Relay-Trailer Tow-Left Connector (IN IPM) RELAY-TRAILER TOW-LEFT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Diagrams > Relay-Trailer Tow-Left > Page 8902 Trailer Towing Relay: Diagrams Relay-Trailer Tow-Right Connector (IN IPM) RELAY-TRAILER TOW-RIGHT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description Trailer Towing Relay: Description and Operation Trailer Tow Relay - Description DESCRIPTION Vehicles equipped with an optional factory-installed trailer towing package have two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Frame > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description > Page 8905 Trailer Towing Relay: Description and Operation Trailer Tow Relay - Operation OPERATION The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays as well as the hard wired inputs and outputs of the relays may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Grille - Removal Grille: Service and Repair Grille - Removal REMOVAL NOTE: Aspen grille shown, Durango grille similar. 1. Remove the front fascia. See: Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Removal 2. Remove the push pin fasteners and remove the upper radiator shroud. 3. Remove the four upper screws (1). 4. Remove the four screws (2) and remove the grille. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Grille - Removal > Page 8910 Grille: Service and Repair Grille - Installation INSTALLATION CAUTION: Do not use a hammer or mallet to install the upper radiator shroud push pins, due to potential damage to the grille. NOTE: Aspen grille shown, Durango grille similar. 1. Install the grille (3). 2. Install the four screws (2) and tighten to 13 Nm (10 ft. lbs.). 3. Install the upper four screws (1) and tighten to 13 Nm (10 ft. lbs.). 4. Install the upper radiator shroud and install the push pin fasteners. 5. Install the front fascia. See: Bumper/Front Bumper/Front Bumper Cover / Fascia/Service and Repair/Front Bumper Fascia - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet - Removal Carpet: Service and Repair Carpet - Removal REMOVAL NOTE: The floor mat hook is serviced separately from the carpet.DO not replace the carpet, due to a broken floor mat hook. 1. Remove the front seats. See: Seats/Service and Repair/Seat, Front/Seat - Removal 2. Remove the floor console. See: Console/Service and Repair/Floor Console - Removal 3. Using a trim stick C-4755 or equivalent, remove the door sill scuff plates. See: Scuff Plate/Description and Operation 4. Remove the cowl trim panels. 5. Fold the second row seats forward and remove the right and left side bolts (1 and 2). 6. Remove the second row seat assembly. 7. Remove the third row seat assembly, if equipped. See: Seats/Service and Repair/Seat, Front/Seat - Removal 8. Remove the bolts (1 and 2) and remove the storage bin, if equipped. 9. Remove the carpet from under the side trim panels. 10. Remove the carpet. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Carpet - Removal > Page 8916 Carpet: Service and Repair Carpet - Installation INSTALLATION 1. Position the carpet in vehicle and tuck up under the side trim panels. 2. Install the third row seat assembly, if equipped. See: Seats/Service and Repair/Seat, Front/Seat - Installation 3. Install the storage bin, if equipped. Tighten the rear screws to 7 Nm (62 in. lbs.). 4. Install the second row seat assembly and install the bolts (1 and 2). 5. Tighten the front bolts (2) to 27 Nm (20 ft. lbs.). 6. Tighten the rear bolts (1) to 47 Nm (35 ft. lbs.). 7. Install the cowl trim panels. 8. Position the door sill scuff plates and seat the clips fully. See: Scuff Plate/Description and Operation 9. Install the floor console. See: Console/Service and Repair/Floor Console Installation 10. Install the front seats. See: Seats/Service and Repair/Seat, Front/Seat - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Description and Operation Console: Description and Operation DESCRIPTION NOTE: The Electronic Vehicle Information Center (EVIC) module is sometimes referred to as the Electronic Overhead Module (EOM) for the purposes of scan tool and diagnostic information naming. Please treat the EVIC and EOM as one and the same when diagnosing the vehicle. NOTE: The overhead console on vehicles with the Light Emitting Diode (LED) lighting package contains three LED units, each with its own dedicated printed circuit board. The two outboard articulating eyeball-type LED reading lamp pod units with their integral lens-actuated switches and printed circuit boards are available for separate service replacement. However, if the fixed center LED unit or printed circuit board is damaged or ineffective, the entire overhead console housing unit must be replaced. NOTE: On overhead consoles with incandescent reading lamps the switches, bulb holders and wiring harness are serviced only as a unit and are not available individually for service. NOTE: On vehicles equipped with both a power sunroof and power liftgate the overhead console switches (1 and 2) are serviced together as one assembly. NOTE: Aspen overhead console with Electronic Vehicle Information Center (EVIC) shown. Durango overhead console similar. An overhead console (4) is available on this vehicle and includes the following components: - Front map/reading lamps (3) - A vacuum-fluorescent display screen (5) - if equipped with EVIC - HomeLink(R) transceiver - if equipped - EVIC Module - if equipped - Power Sunroof Switch (2) - if equipped - Power Liftgate Switch (1) - if equipped - Infrared Temperature Sensor (6) - if equipped The overhead console assembly is mounted by four snap clips securing it to a molded plastic retainer bracket located above the headliner. The EVIC module is accessed by removing the overhead console from the bracket and pulling it away from the headliner. The EVIC module consist of the vacuum-fluorescent display screen, HomeLink(R) transceiver and four function buttons. The individual components of the EVIC module are not serviced separately and if damaged or inoperative, must be replaced as a unit. For additional information on the EVIC module and system, See: Accessories and Optional Equipment/Driver/Vehicle Information Display/Description and Operation/Electronic Vehicle Information Center - Description. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal Console: Service and Repair Overhead Console - Removal Overhead Console OVERHEAD CONSOLE NOTE: The overhead console on vehicles with the Light Emitting Diode (LED) lighting package contains three LED units, each with its own dedicated printed circuit board. The two outboard articulating eyeball-type LED reading lamp pod units with their integral lens-actuated switches and printed circuit boards are available for separate service replacement. However, if the fixed center LED unit or printed circuit board is damaged or ineffective, the entire overhead console housing unit must be replaced. NOTE: On overhead consoles with incandescent reading lamps the switches, bulb holders and wiring harness are serviced only as a unit and are not available individually for service. NOTE: On vehicles equipped with both a power sunroof and power liftgate the overhead console switches (1 and 2) are serviced together as one assembly. NOTE: Aspen overhead console with Electronic Vehicle Information Center (EVIC) shown. Durango overhead console similar. 1. Disconnect and isolate the battery negative cable. 2. Insert the fingertips of both hands between the headliner and the sides of the overhead console housing (4). 3. Pull downward on the sides of the overhead console housing firmly and evenly to disengage the snap clips from the overhead console bracket (2). 4. Lower the overhead console from the headliner (1) far enough to access the wire harness connectors (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8922 5. Disconnect the infrared temperature sensor wire harness connector (1) (if equipped). 6. Disconnect the power sunroof/power liftgate switch wire harness connector (2) (if equipped). 7. Disconnect the reading lamp wire harness connector (3) (if equipped). 8. Disconnect the Electronic Vehicle Information Center (EVIC) module wire harness connector (4) (if equipped). 9. Remove the overhead console from the vehicle. Overhead Console Bracket OVERHEAD CONSOLE BRACKET 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the overhead console bracket. See: . 3. Remove the two screws (4) that secure the front of the overhead console bracket (2) to the roof front header. 4. Remove the overhead console bracket (2) from the headliner (1) by moving it back and forth to free it from it's seat. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8923 Console: Service and Repair Overhead Console - Installation Overhead Console OVERHEAD CONSOLE 1. Position the overhead console near the mounting location on the headliner. 2. Connect the infrared temperature sensor wire harness connector (1) (if equipped). 3. Connect the power sunroof/power liftgate switch wire harness connector (2) (if equipped). 4. Connect the reading lamp wire harness connector (3) (if equipped). 5. Connect the Electronic Vehicle Information Center (EVIC) module wire harness connector (4) (if equipped). 6. Align the snap clips on the overhead console housing with their receptacles in the overhead console bracket (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8924 7. Push upward firmly and evenly on the sides of the overhead console housing (4) over the snap clip locations until the snap clips are fully engaged with the overhead console bracket. 8. Reconnect the battery negative cable. Overhead Console Bracket OVERHEAD CONSOLE BRACKET 1. Install the overhead console bracket (2) to the headliner (1) and roof front header. 2. Install and tighten the two screws (4) that secure the front of the overhead console bracket (2) to the roof front header. Tighten the screws to 1.9 Nm (17 in. lbs.). 3. Install the overhead console, See: . 4. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8925 Console: Service and Repair Rear Center Console - Removal REMOVAL 1. Remove the cup holder insert from the console. 2. Remove the two screws from the front of the console. 3. Using a small flat bladed tool or equivalent remove the console trim panel (1) from the console (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8926 4. Disconnect all electrical connectors (2). 5. Open the console lid and remove the two screws. 6. Remove the side screws from both the left and right sides of the console and remove the console from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8927 Console: Service and Repair Rear Center Console - Installation INSTALLATION 1. Install the console to the vehicle. 2. Install the side screws to both the left and right sides of the console. 3. Install the two screws to the read of the console. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8928 4. Connect all electrical connectors (2) to the console trim panel (1). 5. Install the console trim panel (1) to the console (3). 6. Install the two screws to the front of the console. 7. Install the cup holder insert to the console. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8929 Console: Service and Repair Overhead Console OVERHEAD CONSOLE NOTE: The overhead console on vehicles with the Light Emitting Diode (LED) lighting package contains three LED units, each with its own dedicated printed circuit board. The two outboard articulating eyeball-type LED reading lamp pod units with their integral lens-actuated switches and printed circuit boards are available for separate service replacement. However, if the fixed center LED unit or printed circuit board is damaged or ineffective, the entire overhead console housing unit must be replaced. NOTE: On overhead consoles with incandescent reading lamps the switches, bulb holders and wiring harness are serviced only as a unit and are not available individually for service. NOTE: On vehicles equipped with both a power sunroof and power liftgate the overhead console switches (1 and 2) are serviced together as one assembly. NOTE: Aspen overhead console with Electronic Vehicle Information Center (EVIC) shown. Durango overhead console similar. 1. Disconnect and isolate the battery negative cable. 2. Insert the fingertips of both hands between the headliner and the sides of the overhead console housing (4). 3. Pull downward on the sides of the overhead console housing firmly and evenly to disengage the snap clips from the overhead console bracket (2). 4. Lower the overhead console from the headliner (1) far enough to access the wire harness connectors (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8930 5. Disconnect the infrared temperature sensor wire harness connector (1) (if equipped). 6. Disconnect the power sunroof/power liftgate switch wire harness connector (2) (if equipped). 7. Disconnect the reading lamp wire harness connector (3) (if equipped). 8. Disconnect the Electronic Vehicle Information Center (EVIC) module wire harness connector (4) (if equipped). 9. Remove the overhead console from the vehicle. Overhead Console Bracket OVERHEAD CONSOLE BRACKET 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the overhead console bracket. See: Overhead Console - Removal. 3. Remove the two screws (4) that secure the front of the overhead console bracket (2) to the roof front header. 4. Remove the overhead console bracket (2) from the headliner (1) by moving it back and forth to free it from it's seat. Overhead Console OVERHEAD CONSOLE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8931 1. Position the overhead console near the mounting location on the headliner. 2. Connect the infrared temperature sensor wire harness connector (1) (if equipped). 3. Connect the power sunroof/power liftgate switch wire harness connector (2) (if equipped). 4. Connect the reading lamp wire harness connector (3) (if equipped). 5. Connect the Electronic Vehicle Information Center (EVIC) module wire harness connector (4) (if equipped). 6. Align the snap clips on the overhead console housing with their receptacles in the overhead console bracket (2). 7. Push upward firmly and evenly on the sides of the overhead console housing (4) over the snap clip locations until the snap clips are fully engaged with the overhead console bracket. 8. Reconnect the battery negative cable. Overhead Console Bracket Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8932 OVERHEAD CONSOLE BRACKET 1. Install the overhead console bracket (2) to the headliner (1) and roof front header. 2. Install and tighten the two screws (4) that secure the front of the overhead console bracket (2) to the roof front header. Tighten the screws to 1.9 Nm (17 in. lbs.). 3. Install the overhead console, See: Overhead Console - Installation. 4. Reconnect the battery negative cable. Rear Center Console - Removal REMOVAL 1. Remove the cup holder insert from the console. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8933 2. Remove the two screws from the front of the console. 3. Using a small flat bladed tool or equivalent remove the console trim panel (1) from the console (3). 4. Disconnect all electrical connectors (2). 5. Open the console lid and remove the two screws. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8934 6. Remove the side screws from both the left and right sides of the console and remove the console from the vehicle. Rear Center Console - Installation INSTALLATION 1. Install the console to the vehicle. 2. Install the side screws to both the left and right sides of the console. 3. Install the two screws to the read of the console. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8935 4. Connect all electrical connectors (2) to the console trim panel (1). 5. Install the console trim panel (1) to the console (3). 6. Install the two screws to the front of the console. 7. Install the cup holder insert to the console. Floor Console - Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8936 NAFTA Vehicles 1. Remove the rubber cup holder liners. 2. Remove the front (1), center (2) and rear screws (3). 3. Lift the floor console up and disconnect the electrical connector (4). 4. Slide the floor console back and remove. Export Vehicles 1. Using trim stick C-4755 or equivalent, separate the clips securing the storage bin (1) to the console and remove the storage bin assembly. 2. Remove the front (1), center (3) and rear screws (2). 3. Lift the floor console up and disconnect the electrical connector (4). 4. Slide the floor console back and remove. Floor Console - Installation INSTALLATION NAFTA Vehicles Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Overhead Console - Removal > Page 8937 1. Position the floor console in the vehicle and connect the electrical connector (4). 2. Slide the console forward and engage the front with the instrument panel. 3. Install the screws (3, 2 and 1). 4. Install the rubber cup holder liners. Export Vehicles 1. Position the floor console in the vehicle and connect the electrical connector (4). 2. Slide the console forward and engage the front with the instrument panel. 3. Install the screws (3, 2 and 1). 4. Position the storage bin assembly (1) back onto the console and seat the clips fully. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Glove Box - Removal Glove Compartment: Service and Repair Instrument Panel Glove Box - Removal REMOVAL 1. Open the glove box and squeeze the stop tabs inward. 2. Lower the glove box and release the hinges (1) using a twisting motion and remove the glove box. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Instrument Panel Glove Box - Removal > Page 8942 Glove Compartment: Service and Repair Instrument Panel Glove Box - Installation INSTALLATION 1. Position the glove box and twist the box tabs (2) onto the hinges (1) using a twisting motion as indicated. 2. Close the box and squeeze the stop tabs inward and engage into the instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner - Removal Headliner: Service and Repair Headliner - Removal REMOVAL 1. Disconnect and isolate battery negative cable. 2. Remove the sun visors (5) and disconnect the electrical connectors, if equipped. 3. Remove the A-pillar trim panels. See: Trim Panel/Service and Repair/Pillar Trim/A-Pillar Trim Panel-Removal 4. Remove the overhead console (4), if equipped. See: Console/Service and Repair/Overhead Console - Removal 5. Remove the left upper B-pillar trim. See: Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Removal 6. Remove the left C-pillar trim. See: Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Removal 7. Remove the screws and remove the coat hooks (2). 8. Remove the front seat headrests. 9. Fold both second row seats forward. 10. Place the third row seat into the storage position, if equipped. 11. Remove the dome lamps. See: Lighting and Horns/Dome Lamp/Service and Repair/Dome Lamp - Removal 12. Remove the DVD player, if equipped. See: Accessories and Optional Equipment/Entertainment Systems/Service and Repair/Media System Removal 13. Remove the push pin fastener at the rear of the headliner. 14. Remove the sunroof opening trim lace (3), if equipped. See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Interior Trim Panel/Service and Repair/Sunroof Trim Lace - Removal 15. Drop the headliner down and disconnect the electrical connectors. 16. Disconnect the front and rear washer hoses and remove the headliner through the liftgate opening. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Headliner - Removal > Page 8947 Headliner: Service and Repair Headliner - Installation INSTALLATION 1. Place headliner into the vehicle through the liftgate opening and connect the front and rear washer hoses (1). 2. Connect the electrical connectors. 3. Install the sunroof opening trim lace (3), if equipped. See: Roof and Associated Components/Sunroof / Moonroof/Sunroof / Moonroof Interior Trim Panel/Service and Repair/Sunroof Trim Lace - Installation 4. Install the push pin fastener at the rear of the headliner. 5. Install the DVD player, if equipped. See: Accessories and Optional Equipment/Entertainment Systems/Service and Repair/Media System Installation 6. Install the dome lamps. See: Lighting and Horns/Dome Lamp/Service and Repair/Dome Lamp Installation 7. Install the front seat headrests. 8. Install the screws and install the coat hooks (2). 9. Install the C-pillar trim. See: Trim Panel/Service and Repair/Pillar Trim/C-Pillar Trim Panel-Installation 10. Install the upper B-pillar trim. See: Trim Panel/Service and Repair/Pillar Trim/B-Pillar Trim Panel-Installation 11. Install the overhead console, if equipped. See: Console/Service and Repair/Overhead Console - Installation 12. Install the A-pillar trim panels. See: Trim Panel/Service and Repair/Pillar Trim/A-Pillar Trim Panel-Installation 13. Connect the electrical connectors and install the sun visors (5). 14. Connect battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Description and Operation > Door Scuff Plate: Description and Operation Door DESCRIPTION SCUFF PLATES Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Description and Operation > Door > Page 8952 Scuff Plate: Description and Operation Liftgate DESCRIPTION LIFTGATE SCUFF PLATE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Description and Operation > Cowl Trim Panel - Description Trim Panel: Description and Operation Cowl Trim Panel - Description DESCRIPTION COWL TRIM PANEL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Description and Operation > Cowl Trim Panel - Description > Page 8957 Trim Panel: Description and Operation Rear Header Panel - Description DESCRIPTION REAR HEADER TRIM Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Luggage Compartment Trim Trim Panel: Service and Repair Luggage Compartment Trim Lower REMOVAL 1. Remove the D-pillar trim. See: Pillar Trim/D-Pillar Trim/Removal 2. Remove the screws (3). 3. Slide the trim panel (2) off the retaining tabs (1) and remove. Upper REMOVAL 1. Remove the C-pillar trim. See: Pillar Trim/C-Pillar Trim Panel-Removal 2. Remove the rear screw (1). 3. Remove the tie down anchor bolt (2) and tie down (3). 4. Remove the three front screws (4) and separate the trim panel. 5. Disconnect the power outlet electrical connector, if equipped. Lower Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Luggage Compartment Trim > Page 8960 INSTALLATION 1. Position the trim panel (2) over the retaining tabs (1) and slide into place fully. 2. Install the screws (3). 3. Install the D-pillar trim. See: Pillar Trim/D-Pillar Trim/Installation Upper INSTALLATION 1. Connect the power outlet electrical connector, if equipped. 2. Position the trim panel onto the quarter panel and seat the retaining clips fully. 3. Install the three forward screws (4). 4. Install the rear screw (1). 5. Install the tie down (3) and tie down anchor bolt (2). 6. Tighten the bolt to 12 Nm (9 ft. lbs.) 7. Install the C-pillar trim. See: Pillar Trim/C-Pillar Trim Panel-Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Luggage Compartment Trim > Page 8961 Trim Panel: Service and Repair Pillar Trim A-Pillar Trim Panel-Removal REMOVAL 1. Using a small flat bladed tool or equivalent open the trim plugs (2) in the A-pillar grab handle and remove the bolts (3). 2. Remove the A-pillar trim panel (1). A-Pillar Trim Panel-Installation INSTALLATION 1. Position the A-pillar trim (1) into place and seat the retaining clips fully. 2. Install the bolts and tighten to 6 Nm (55 in. lbs.). B-Pillar Trim Panel-Installation INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Luggage Compartment Trim > Page 8962 1. Position the shoulder belt through the upper slot in the trim. 2. Install the trim panel and install the bolts. 3. Position the door sill scuff plates and seat the clips fully. See: Scuff Plate/Description and Operation 4. Position the upper trim panel tab (1) into the B-pillar and seat the lower side of the trim fully. 5. Install the shoulder belt anchor bolt (3) and tighten to 39 Nm (29 ft. lbs.). 6. Engage the tab (2) on the lower edge of the trim cover (3) in the slot below the screw in the turning loop (1). Then press the upper edge of the trim cover over the top of the turning loop until it snaps into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Luggage Compartment Trim > Page 8963 7. Install the grab handle bolts (2) and tighten to 6 Nm (55 in. lbs.). B-Pillar Trim Panel-Removal REMOVAL 1. Using a small flat bladed tool or equivalent open the trim plugs (1) in the grab handle and remove the bolts (2). 2. Remove the shoulder belt anchor bolt (3) and separate the upper trim panel (2) at the bottom and off the hook (1) at the top. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Luggage Compartment Trim > Page 8964 3. Using a trim stick C-4755 or equivalent, remove the door sill scuff plates. See: Scuff Plate/Description and Operation 4. Remove the bolts and remove the lower B-pillar trim. C-Pillar Trim Panel-Removal REMOVAL 1. Remove the quarter glass trim panel. See: Luggage Compartment Trim/Quarter Trim Panel Removal. 2. Unsnap the upper edge of the trim cover (3) from the second row outboard seat belt turning loop (1) and disengage the tab (2) on the lower edge of the cover to access the turning loop screw. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Luggage Compartment Trim > Page 8965 3. Remove the screw (3) that secures the seat belt turning loop (4) to the height adjuster (1) on the upper C-pillar (5). 4. Remove the screw (3). 5. Using a trim stick C-4755 or equivalent, separate the bottom edge of the trim (2) from the pillar and remove off of the upper locating tab (1). C-Pillar Trim Panel-Installation INSTALLATION 1. Position the upper trim panel tab (1) into the C-pillar and seat the lower side of the trim fully. 2. Install the screw (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Luggage Compartment Trim > Page 8966 3. Position the seat belt turning loop (4) to the height adjuster (1). 4. Install the screw (3) and tighten the to 39 Nm (29 ft. lbs.). 5. Engage the tab (2) on the lower edge of the trim cover (3) in the slot below the screw in the turning loop (1). Then press the upper edge of the trim cover over the top of the turning loop until it snaps into place. Removal REMOVAL 1. Remove the third row seat as necessary to access to the seat belt lower anchor (2) on the quarter inner panel (3). See: Seats/Service and Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Luggage Compartment Trim > Page 8967 Repair/Seat, Front/Seat - Removal 2. Remove the bolt (1) and separate the seat belt anchor (2). 3. Using a trim stick C-4755 or equivalent, separate the retaining clips and remove the upper rear header trim. See: Description and Operation/Rear Header Panel - Description 4. Remove the screw (1). 5. Using a trim stick C-4755 or equivalent, separate the trim (2), retaining clips and anchor (3). 6. Remove the D-pillar trim (2) and pull the belt through the panel. Installation INSTALLATION 1. Position the seat belt through the hole in the D-pillar trim (2). 2. Position the D-pillar trim (2) in place on the D-pillar and anchor (3). 3. Seat the retaining clips fully and install the screw (1). 4. Position the rear header trim in place and seat the retaining clips fully. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Luggage Compartment Trim > Page 8968 5. Position the seat belt lower anchor (2) to the tapping plate (3) on the quarter inner panel. 6. Install the screw (1) securing the lower anchor to the tapping plate and tighten the to 39 Nm (29 ft. lbs.). 7. Install the third row seat if necessary. See: Seats/Service and Repair/Seat, Front/Seat Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Locations > Driver Door Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Locations > Driver Door Module > Page 8975 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Driver Door Module C1 (Front Driver Door) 10 Way Door Module: Diagrams Driver Door Module C1 (Front Driver Door) 10 Way Connector C1 - (FRONT DRIVER DOOR) 10 WAY MODULE-DOOR-DRIVER - (FRONT DRIVER DOOR) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Driver Door Module C1 (Front Driver Door) 10 Way > Page 8978 Door Module: Diagrams Driver Door Module C2 (Front Driver Door) 20 Way Connector C2 - (FRONT DRIVER DOOR) 20 WAY MODULE-DOOR-DRIVER - (FRONT DRIVER DOOR) 20 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Driver Door Module C1 (Front Driver Door) 10 Way > Page 8979 Door Module: Diagrams Driver Door Module C3 (Front Driver Door) 12 Way Connector C3 - (FRONT DRIVER DOOR) 12 WAY MODULE-DOOR-DRIVER - (FRONT DRIVER DOOR) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Driver Door Module C1 (Front Driver Door) 10 Way > Page 8980 Door Module: Diagrams Passenger Door Module C1 (Front Passenger Door) 10 Way Connector C1 - (FRONT PASSENGER DOOR) 10 WAY MODULE-DOOR-PASSENGER - (FRONT PASSENGER DOOR) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Diagrams > Driver Door Module C1 (Front Driver Door) 10 Way > Page 8981 Door Module: Diagrams Passenger Door Module C2 (Front Passenger Door) 20 Way Connector C2 - (FRONT PASSENGER DOOR) 20 WAY MODULE-DOOR-PASSENGER - (FRONT PASSENGER DOOR) 20 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Description and Operation > Door Module - Description Door Module: Description and Operation Door Module - Description DESCRIPTION There are two Door Modules, Driver Door Module (DDM) and Passenger Door Modules (PDM). One located in the driver door and one in the passenger door, just behind the door trim panel. The modules send a bus message to the power mirrors to adjust them to a preset position when a memory recall request has been made. The memory mirror modules also act as an interface in each door for electrical functions (door lock switches and door ajar switches). The Memory System makes available for immediate recall personalized preferences of the following: - Automatic temperature control settings. - Outside mirror positions. - Power adjustable brake and accelerator pedal position. - Power seat horizontal, vertical, recliner, and easy entry positions. - Radio push button station selections. The major components of the Memory System are: - Memory Selector Switch - located in the driver door trim panel. - Driver Door Module (DDM) - located in the driver door, behind the trim panel. - Passenger Door Module (PDM) - located in the passenger door, behind the trim panel. - Sentry Key Remote Entry Module (SKREEM) - located at ignition key cylinder. - Remote Keyless Entry (RKE) Transmitter - located with ignition key. - Memory Seat Module (MSM) - located underneath the driver seat and also controls the Adjustable Pedals. - Radio - located in the instrument panel center stack. - Automatic Temperature Control (ATC) - located in the instrument panel center stack. The memory recall is available at the press of a button on the drivers door trim panel or, by using the Remote Keyless Entry (RKE) transmitter if it is programmed to trigger the recall. Radio settings include up to 20 push button presets (10 AM and 10 FM), and the last station selection, even if it is not one of the 20 preset selections. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Description and Operation > Door Module - Description > Page 8984 Door Module: Description and Operation Door Module - Operation OPERATION The door modules receives input from the door lock switches and sends that message to the cluster for door lock operation (vehicles equipped with memory system only). It also controls the mirror adjustment by receiving input from the mirror switch on the door trim panel. Sensors in the mirrors act as inputs to the memory mirror module in order to position the mirrors to presets by the driver(s). The power supply to the mirrors is supplied by the door modules. On vehicles equipped with a memory system, the front door ajar switches are inputs to the door module. The modules use this information for door lock inhibit etc. A memory setting is saved by pressing the "set" button, then pressing either the memory "1" or "2" button within 5 seconds of pressing the "set" button. A memory setting is recalled by pressing either the memory "1" or "2" button, or by pressing the unlock button on a "linked" Remote Keyless Entry (RKE) transmitter. For driver safety, memorized settings can not be recalled if the transmission is in a position other than Park or the seat belt is latched. Both driver and passenger modules provide active and stored Diagnostic Trouble Codes (DTC's) to aid in diagnosis. Both modules are identical in appearance with the exception of an extra ground wire on the driver side memory mirror module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Testing and Inspection > Component Tests and General Diagnostics Door Module: Component Tests and General Diagnostics DOOR MODULE Any diagnosis of the memory mirror module should begin with the use of a scan tool and the appropriate Diagnostic information. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Service and Repair > Door Module - Removal Door Module: Service and Repair Door Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Removal. 3. First disconnect the black 10-way electrical connector (1), then the brown 20-way electrical connector (2). If applicable, next disconnect the black 12-way electrical connector (3) from the module. 4. Remove fasteners and module from vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Door Locks > Door Module > Component Information > Service and Repair > Door Module - Removal > Page 8989 Door Module: Service and Repair Door Module - Installation INSTALLATION 1. Position module on door and install fasteners. 2. If applicable, first connect the black 12-way electrical connector (3), then connect the brown 20-way electrical connector (2). Then connect the black 10-way electrical connector to the module (1). 3. Install the door trim panel See: Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Trim Panel Installation. 4. Connect the battery negative cable. 5. Verify system and vehicle operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 8994 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY MODULE-WIRELESS CONTROL - (INSTRUMENT PANEL) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 8995 Keyless Entry Module: Testing and Inspection SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations > Page 8996 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Description and Operation Keyless Start Antenna: Description and Operation DESCRIPTION The Remote Start Antenna Module Assembly consists of an electrical connection to the WCM/SKREEM (1), a length of coax cable (2), two mounting clips (3) and (4), and a control module/antenna (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal Keyless Start Antenna: Service and Repair Remote Start Antenna - Removal REMOVAL The Remote Start Antenna Module Assembly consists of an electrical connection to the WCM/SKREEM (1), a length of coax cable (2), two mounting clips (3) and (4), and a control module/antenna (5). The control module (3) is located under the instrument panel cover (2). The module electrical connector plugs into the WCM/SKREEM at the right side of the steering column. 1. Disconnect and isolate negative battery cable. 2. Remove steering column trim panel (knee blocker). 3. Remove steering column shrouds. 4. Remove left instrument panel (IP) end cap. 5. Remove IP cluster bezel. 6. Remove IP cluster and its three connectors. 7. Remove left A-pillar trim. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 9003 8. Unclip upper IP bezel (defroster). 9. Remove two module mounting screws (4) from module (3). 10. Disconnect coax cable retainers (3) and (4) from IP. 11. Remove two WCM/SKREEM mounting screws at steering column (1). 12. Remove WCM/SKREEM from steering column (1). 13. Disconnect coax cable electrical connector (2) at WCM/SKREEM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 9004 14. Remove module (2) from top of instrument panel while fishing coax cable (1) through openings. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 9005 Keyless Start Antenna: Service and Repair Remote Start Antenna - Installation INSTALLATION The Remote Start Antenna Module Assembly consists of an electrical connection to the WCM/SKREEM (1), a length of coax cable (2), two mounting clips (3) and (4), and a control module/antenna (5). 1. Fish coax cable (1) through openings on top of instrument panel. Position module (2) to top of instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 9006 2. Install two module mounting screws (4) to module (3). 3. Connect coax cable retainers (3) and (4) to instrument panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Starting System > Keyless Start Antenna > Component Information > Service and Repair > Remote Start Antenna - Removal > Page 9007 4. Connect coax cable electrical connector (2) to WCM/SKREEM. 5. Install WCM/SKREEM to steering column (1). 6. Clip upper instrument panel (IP) bezel (defroster). 7. Install left A-pillar trim. 8. Install IP cluster and its three connectors. 9. Install IP cluster bezel. 10. Install left IP end cap. 11. Install steering column trim panel (knee blocker). 12. Install steering column shrouds. 13. Connect negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair REMOTE KEYLESS ENTRY TRANSMITTER BATTERIES The Remote Keyless Entry (RKE) transmitter case snaps open and shut for battery access. To replace the RKE transmitter batteries: 1. Using a trim stick or a thin coin, gently pry at the notch in the center seam of the RKE transmitter case halves located near the key ring until the two halves unsnap. 2. Lift the back half of the transmitter case off of the RKE transmitter. 3. Remove the two batteries from the RKE transmitter. 4. Replace the battery with a new CR2032. Be certain that the battery is installed with the polarity correctly oriented. 5. Align the two RKE transmitter case halves with each other, and squeeze them firmly and evenly together using hand pressure until they snap back into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Left Front Door Latch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Left Front Door Latch > Page 9017 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Left Front Door Latch > Page 9018 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Locations > Left Front Door Latch > Page 9019 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Left Front Door Latch (Front Driver Door) 4 Way Power Door Lock Actuator: Diagrams Left Front Door Latch (Front Driver Door) 4 Way Connector - (FRONT DRIVER DOOR) 4 WAY LATCH-DOOR-LEFT FRONT - (FRONT DRIVER DOOR) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Left Front Door Latch (Front Driver Door) 4 Way > Page 9022 Power Door Lock Actuator: Diagrams Left Rear Door Latch (Left Rear Door) 4 Way Connector - (LEFT REAR DOOR) 4 WAY LATCH-DOOR-LEFT REAR - (LEFT REAR DOOR) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Left Front Door Latch (Front Driver Door) 4 Way > Page 9023 Power Door Lock Actuator: Diagrams Right Front Door Latch (Front Passenger Door) 4 Way Connector - (FRONT PASSENGER DOOR) 4 WAY LATCH-DOOR-RIGHT FRONT - (FRONT PASSENGER DOOR) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Left Front Door Latch (Front Driver Door) 4 Way > Page 9024 Power Door Lock Actuator: Diagrams Right Rear Door Latch (Right Rear Door) 4 Way Connector - (RIGHT REAR DOOR) 4 WAY LATCH-DOOR-RIGHT REAR - (RIGHT REAR DOOR) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Door Lock Motor - Description Power Door Lock Actuator: Description and Operation Door Lock Motor - Description DESCRIPTION The lock mechanisms are actuated by a reversible electric motor mounted within each door. The power lock motors are integral to the door latch units. The power lock motors cannot be adjusted or repaired and, if faulty or damaged, the door latch unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Door Lock Motor - Description > Page 9027 Power Door Lock Actuator: Description and Operation Door Lock Motor - Operation OPERATION The door lock motors are controlled by the instrument cluster. A positive and negative battery connection to the two motor terminals will cause the motor to move in one direction. Reversing the current will cause the motor to move in the opposite direction. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Description and Operation > Page 9028 Power Door Lock Actuator: Testing and Inspection POWER LOCK MOTOR The most reliable, efficient, and accurate means to diagnose the power lock system requires the use of a scan tool and the proper Diagnostic Procedures information. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Driver Window/Door Lock Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Driver Window/Door Lock Switch > Page 9033 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Left Front Door) 8 Way Power Door Lock Switch: Diagrams Driver Window/Door Lock Switch C1 (Left Front Door) 8 Way Connector C1 - (LEFT FRONT DOOR) 8 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (LEFT FRONT DOOR) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Left Front Door) 8 Way > Page 9036 Power Door Lock Switch: Diagrams Driver Window/Door Lock Switch C2 (Left Front Door) 6 Way Connector C2 - (LEFT FRONT DOOR) 6 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (LEFT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Left Front Door) 8 Way > Page 9037 Power Door Lock Switch: Diagrams Passenger Window/Door Lock Switch (Right Front Door) 6 Way Connector - (RIGHT FRONT DOOR) 6 WAY SWITCH-WINDOW/DOOR LOCK-PASSENGER - (RIGHT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation > Power Lock Switch - Description Power Door Lock Switch: Description and Operation Power Lock Switch - Description DESCRIPTION A window/lock switch located in each front door trim panel. The driver's side window/lock switch includes the following: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, the window/lock switch houses individual master switches for each passenger door power window. The passenger side window/lock switch includes the following: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Window Switch - A two-way, momentary power window switch for the passenger side front door. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation > Power Lock Switch - Description > Page 9040 Power Door Lock Switch: Description and Operation Power Lock Switch - Operation OPERATION The driver side window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single assembly. The switches in the window/lock switch can be diagnosed using conventional diagnostic tools and methods. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster (without memory). If equipped with the memory system, the circuitry is connected to the memory mirror module. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster or memory mirror input, which allows the instrument cluster or memory module to sense the switch position. Based upon the power lock switch input, the instrument cluster or memory module controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch in the window/lock switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch in the window/lock switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the switches in the window/lock switch. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Description and Operation > Page 9041 Power Door Lock Switch: Testing and Inspection WINDOW/DOOR LOCK SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the window/lock switch power window and power lock switches receive battery current through the circuit breaker in the Integrated Power Module (IPM). If only one LED in the door module is inoperative, replace the faulty door module. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty window/lock switch. Refer to the appropriate wiring information. 1. Disconnect and isolate the negative battery cable. Remove the window/lock switch from the door trim panel. Disconnect the door wire electrical connectors from the switch. 2. Test the switch continuity. See the Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty window/lock switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal Power Door Lock Switch: Service and Repair Power Lock Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, start at the rear of the switch and pry up to remove from door trim panel. 3. Disconnect electrical harness connectors from switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal > Page 9044 Power Door Lock Switch: Service and Repair Power Lock Switch - Installation INSTALLATION 1. Connect electrical harness connectors to switch. 2. Insert front end of switch into door trim panel opening. Press into place. 3. Connect battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way Memory Positioning Module: Diagrams Memory Seat Module C1 (Left Seat) 14 Way Connector C1 - (LEFT SEAT) 14 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 9052 Memory Positioning Module: Diagrams Memory Seat Module C2 (Left Seat) 6 Way Connector C2 - (LEFT SEAT) 6 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 9053 Memory Positioning Module: Diagrams Memory Seat Module C3 (Left Seat) 14 Way Connector C3 - (LEFT SEAT) 14 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 9054 Memory Positioning Module: Diagrams Memory Seat Module C4 (Left Seat) 6 Way Connector C4 - (LEFT SEAT) 6 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 9055 Memory Positioning Module: Diagrams Memory Seat Module C5 (Adjustable Pedals) 6 Way Connector C5 (ADJUSTABLE PEDALS) - 6 WAY MODULE-SEAT MEMORY (ADJUSTABLE PEDALS) - 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Description and Operation > Memory Seat Module - Description Memory Positioning Module: Description and Operation Memory Seat Module - Description DESCRIPTION NOTE: The scan tool standardization process must be performed on the Memory Seat Module (MSM) any time a new module is installed or the existing module is reflashed. The Memory Seat Module (MSM) is located underneath the driver seat, towards the front and on the outboard side. It is used in conjunction with the other modules in the memory system See: Memory Seat Module - Operation to recall the seat to one of two preset seat functional adjustments (horizontal, vertical, and recliner). The switch for the memory seat programming and selection mounts on the driver door trim panel. The MSM also controls the adjustable pedals, both for the memory and manual functionality. The adjustable accelerator and brake pedals are available on SLT and Limited models. On Limited, their positioning can be stored for recall by the memory system, allowing for two drivers to have unique, pre-programmed settings. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Description and Operation > Memory Seat Module - Description > Page 9058 Memory Positioning Module: Description and Operation Memory Seat Module - Operation OPERATION POWER/MEMORY SEAT The memory seat module receives input from the 8-way power seat switch, the driver seat position sensors, adjustable pedal control circuits (switch, sensor, and motor), and the data bus circuit. The memory switch, is wired to the memory mirror module which sends the message over the data bus. The memory seat module performs the following functions: - Positions the driver seat (vertical, horizontal, and recliner positions) and adjustable pedals. - Sends the memory save or recall (#1 or #2) command over the data bus circuit to the memory mirror modules, HVAC, and radio. - Provides for "linking" the key FOBs to memory. - Provides for the easy entry/exit feature. - Provides the tilt mirrors in reverse feature When a memory button is pressed (#1 or #2) on the memory switch, the driver door memory mirror module sends a recall message to the memory seat module (MSM). Then the MSM will position the driver seat and adjustable pedals to its preprogrammed location/setting. When the Remote Keyless Entry (RKE) Transmitter button is pressed, depending on which transmitter (#1 or #2), the SKREEM (RKE Receiver) sends the recall request and FOB number (#1 or #2) data message. This RKE transmitter function depends on if the MSM is programmed to trigger the recall (linked FOBs). A memory setting is saved by pressing the "set" button, then pressing either the memory "1" or "2" button within 5 seconds of pressing the "set" button. A memory setting is recalled by pressing either the memory "1" or "2" button, or by pressing the unlock button on a "linked" Remote Keyless Entry (RKE) transmitter. For driver safety, memorized settings can not be recalled if the transmission is in any position other than park or the seat belt is latched. A key FOB is "linked" to a memory setting by pressing the "set" button and then pressing either the memory "1" or "2" button within 5 seconds of pressing the set button, then by pressing the "lock" button on the selected key FOB. The memory system "Easy Entry and /Exit" feature provides the driver with more room to enter or exit the vehicle. The Easy Entry and Exit feature is disabled when the vehicle leaves the factory. An authorized dealer can enable this feature. When the seat is in a memorized position, it will move rearward 55 millimeters or to the end of its travel, whichever occurs first, when the key is removed from the ignition switch lock cylinder. The seat will return to the memory position when the driver turns the vehicle's ignition switch out of the LOCK position. The memory system "learns" the seat and adjustable pedal motor maximum end positions when the motor reaches the limit of travel in any direction and stalls. Subsequently, movement will stop just short of that position to avoid extra stress on the motors and mechanisms. If the system learned a maximum position as a result of an obstruction, as for instance if a large object was placed on the floor behind the seat, the system can relearn the "true" maximum position through manually operating the power seat after the obstruction is removed. NOTE: It is normal for the power accessories contained in the memory system to stop at the maximum "learned" position and then continue to the "true" maximum position when the control switch is released and then applied in the same direction a second time. Certain functions and features of the memory system rely upon resources shared with other electronic modules in the vehicle over the Controller Area Network (CAN) bus. The CAN bus allows the sharing of sensor information. This helps to reduce wire harness complexity, internal controller hardware, and component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. For diagnosis of these electronic modules or of the CAN bus, the use of a scan tool and the proper diagnostic information are needed. The tilt mirrors in reverse feature provides for tilting the sideview (outside) mirrors down a predetermined angle, providing a better view of the ground next to the rear portion of the vehicle. The tilt mirrors in reverse feature is disabled when the vehicle leaves the factory. An authorized dealer can enable this feature. Operation of the tilt mirrors is as follows: - Sideview mirrors will tilt down when the vehicle transmission is shifted into Reverse. - Sideview mirrors will return to the original position when the vehicle transmission is shifted out of Reverse. ADJUSTABLE PEDALS The pedals swing on a large arc, the radius and angle of which were selected on the basis of ergonomic studies, that puts them in the proper position for use by the smaller driver - higher and angled upward as well as rearward. Powered by the small electric motor driving a gear train at each pedal, adjustment is precise, quiet, and smooth throughout the range. A paddle-type switch on the instrument panel to the left of the steering column actuates the electric motor-driven mechanism through the memory seat module (MSM). Pushing up the paddle brings the pedals closer and vice versa. Movement Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Description and Operation > Memory Seat Module - Description > Page 9059 stops when the switch is released. MSM logic prevents pedal adjustment when the automatic speed control (cruise control) is set (controlling speed), and when the transmission is in reverse. This feature protects against a loss of reference position when neither foot is on the pedal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Description and Operation > Page 9060 Memory Positioning Module: Testing and Inspection MEMORY SEAT MODULE Any diagnosis of the memory seat system/module should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Module - Removal Memory Positioning Module: Service and Repair Memory Seat Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver seat cushion/cover (2) See: Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 3. Unsnap the memory seat module (4) from the side brackets. 4. Pivot the module upward and disconnect the electrical connectors (1). 5. Pull the module rearward to remove it from the front of the seat frame (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Module - Removal > Page 9063 Memory Positioning Module: Service and Repair Memory Seat Module - Installation INSTALLATION 1. Place the module (4) into position making sure the front snaps into the seat frame (3). 2. Connect the memory seat module harness connectors (1). 3. Pivot the module (4) downward and snap it into place in the side brackets. 4. Install the driver seat cushion/cover (2) See: Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Installation. 5. Connect the battery negative cable. 6. Using an appropriate scan tool go to the MSM miscellaneous functions and perform the standardization routine. 7. Verify system and vehicle operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 9067 Seat Memory Switch: Diagrams Connector - (LEFT FRONT DOOR) 6 WAY SWITCH-MEMORY SELECTOR - (LEFT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID Paint: Application and ID SPECIFICATIONS - PAINT CODES EXTERIOR COLORS INTERIOR COLORS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Description and Operation > Basecoat/Clearcoat Finish - Description Paint: Description and Operation Basecoat/Clearcoat Finish - Description DESCRIPTION The original equipment paint finish is a multi step process that involves cleaning, applying electro de-position (E-coat), anti-chip primer, basecoat, and clearcoat steps. CAUTION: Do not use abrasive chemicals, abrasive compounds or harsh alkaline based cleaning solvents on the painted surfaces of a vehicle. Failure to follow this caution can result in damage to vehicle finish. On most vehicles a two-part paint application (basecoat/clearcoat) is used. Color paint that is applied to primer is called basecoat. A clear coat paint is then applied to protect the basecoat from ultraviolet light and to provide a durable high-gloss finish. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Description and Operation > Basecoat/Clearcoat Finish - Description > Page 9074 Paint: Description and Operation Paint Touch-up - Description DESCRIPTION When a painted metal surface has been scratched or chipped, it should be touched-up as soon as possible to avoid corrosion. For best results, use MOPAR(R) Scratch Filler/Primer, Touch-Up Paints and Clear Top Coat. WARNING: Use an OSHA approved respirator and safety glasses when spraying paint or solvents in a confined area. Personal injury can result. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up Paint: Service and Repair Paint Touch-Up PAINT TOUCH-UP 1. Scrape loose paint and corrosion from inside scratch or chip. 2. Clean affected area with MOPAR(R) Tar/Road Oil Remover or equivalent, and allow to dry. 3. Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle-fill the scratch or chip without running. Do not stroke brush applicator on body surface. Allow the filler/primer to dry hard. 4. Cover the filler/primer with color touch-up paint. Do not overlap touch-up color onto the original color coat around the scratch or chip. Butt the new color to the original color, if possible. Do not stroke applicator brush on body surface. Allow touch-up paint to dry hard. 5. On vehicles without clearcoat, the touch-up color can be lightly finesse sanded (1500 grit) and polished with rubbing compound. 6. On vehicles with clearcoat, apply clear top coat to touch-up paint with the same technique as described in 4. Allow clear top coat to dry hard. If desired, 5 can be performed on clear top coat. WARNING: Avoid prolonged skin contact with petroleum or alcohol - based cleaning solvents. Personal injury can result. Avoid prolonged skin contact with petroleum or alcohol - based cleaning solvents. Personal injury can result. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service and Repair > Paint Touch-Up > Page 9077 Paint: Service and Repair Finesse Sanding, Buffing, And Polishing - Description DESCRIPTION CAUTION: Do not remove more than 0.5 mils of clearcoat finish when sanding, hand buffing or polishing. Basecoat paint must retain clearcoat for durability. CAUTION: If the finish has been finesse sanded in the past, it cannot be repeated. Failure to follow this caution can result in damage to vehicle finish. NOTE: Finesse sanding should only be performed by a trained automotive paint technician. Minor acid etching, orange peel, or smudging in a clearcoat or single-stage finish can be reduced with light finesse sanding, hand buffing and polishing. Use a Paint Thickness Gauge #PR-ETG-2X or equivalent to determine clearcoat or single-stage paint thickness before and after the repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Radiator Upper Crossmember - Installation Radiator Support: Service and Repair Radiator Upper Crossmember - Installation INSTALLATION 1. Install upper crossmember (1). 2. Install outer mounting bolts and tighten. 3. Install nuts attaching latch to radiator crossmember support. Tighten nuts to 31 Nm (23 ft. lbs.) torque. 4. Check hood fit and adjust if required. 5. Install hood seal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Radiator Support > Component Information > Service and Repair > Radiator Upper Crossmember - Installation > Page 9082 Radiator Support: Service and Repair Radiator Upper Crossmember - Removal REMOVAL 1. Raise hood. 2. Remove the front hood seal. 3. Remove the center brace mounting nuts and remove hood latch. 4. Remove the crossmember mounting bolts (2). 5. Remove crossmember (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 9087 Keyless Entry Module: Diagrams Connector - (INSTRUMENT PANEL) 8 WAY MODULE-WIRELESS CONTROL - (INSTRUMENT PANEL) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 9088 Keyless Entry Module: Testing and Inspection SKREEM PROGRAMMING When a Powertrain Control Module (PCM) for a gasoline engine, or an Engine Control Module (ECM) for a diesel engine and the Sentry Key Remote Entry Module (SKREEM) (also known as the Wireless Control Module/WCM) on vehicles equipped with the Sentry Key Immobilizer System (SKIS) are replaced at the same time, perform the following steps in order: NOTE: If the PCM and the SKREEM are replaced at the same time, program the PCM VIN into the PCM first. 1. If applicable first replace the PCM/ECM with the original WCM still connected to the vehicle. 2. Using the appropriate service information program the new PCM/ECM. (This will ensure the Secret Key Transfer from the original WCM into the new PCM/ECM). 3. Now replace and program the WCM. This will retain the Secret Key from the PCM/ECM back into the new WCM. 4. With the scan tool, select Miscellaneous Functions, WCM/Wireless Control Module. Then select the desired procedure and follow the display on the scan tool. 5. If the vehicle is equipped with Tire Pressure Monitoring System program the Placard Pressure Values into the WCM/SKREEM. 6. Ensure all the customer's keys have been programmed into the new module if necessary. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. PROGRAMMING THE SKREEM The SKIS Secret Key is an ID code that is unique to each SKREEM/WCM. This code is programmed and stored in the SKREEM/WCM, the PCM/ECM, and each ignition key transponder chip. When the PCM/ECM or SKREEM/WCM is replaced, it is necessary to program the Secret Key into the new module using a diagnostic scan tool. Follow the programming steps outlined in the diagnostic scan tool for PCM REPLACED, ECM REPLACED, WCM REPLACED, or GATEWAY REPLACED under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item as appropriate. NOTE: Programming the PCM/ECM or SKREEM is done using a diagnostic scan tool and a PIN to enter secure access mode. If three attempts are made to enter secure access mode using an incorrect PIN, secure access mode will be locked out for one hour. To exit this lockout mode, turn the ignition to the RUN position for one hour then enter the correct PIN. Be certain that all accessories are turned OFF. Also monitor the battery state and connect a battery charger if necessary. NOTE: Before replacing the ECU for a failed driver, control circuit or ground circuit, be sure to check the related component/circuit integrity for failures not detected due to a double fault in the circuit. Most ECM driver/control circuit failures are caused by internal component failures (i.e. relay and solenoids) and shorted circuits (i.e. pull-ups, drivers and switched circuits). These failures are difficult to detect when a double fault has occurred and only one DTC has set. ECM/SKIM/WCM PROGRAMMING When a ECM and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM 3. Replace all ignition keys and program them to the new SKIM. ECM/SKIM/WCM PROGRAMMING When an ECM (Bosch) and the SKIM are replaced at the same time perform the following steps in order: 1. Program the new SKIM 2. Program the new ECM (Bosch) 3. Replace all ignition keys and program them to the new SKIM. PROGRAMMING THE SKIM CAUTION: Read all notes and cautions for programming procedures. 1. Connect a battery charger to the vehicle. 2. Connect the StarSCAN(R). CAUTION: If the ECM/PCM and SKREEM/WCM are replaced at the same time, the ECM/PCM MUST be programmed before the SKREEM/WCM. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations > Page 9089 3. Select "ECU View". 4. Select "WCM Wireless Control Module". 5. Select "Miscellaneous Functions". 6. Select WCM replaced. 7. Enter the PIN when prompted. 8. Verify the correct information. NOTE: If the ECM and the SKIM are replaced at the same time, all vehicle keys will need to be replaced and programmed to the new SKIM. PROGRAMMING IGNITION KEYS TO THE SKREEM Each ignition key transponder also has a unique ID code that is assigned at the time the key is manufactured. When a key is programmed into the SKREEM/WCM, the transponder ID code is learned by the module and the transponder acquires the unique Secret Key ID code from the SKREEM/WCM. To program ignition keys into the SKREEM/WCM, follow the programming steps outlined in the diagnostic scan tool for PROGRAM IGNITION KEYS OR KEY FOBS under MISCELLANEOUS FUNCTIONS for the WIRELESS CONTROL MODULE/WCM menu item. NOTE: If the original keys do not successfully program to the new SKREEM after the proper procedures are followed correctly, programming new keys will be necessary. NOTE: A maximum of eight keys can be learned to each SKREEM. Once a key is learned to a SKREEM, that key has acquired the Secret Key for that SKREEM and cannot be transferred to any other SKREEM or vehicle. If ignition key programming is unsuccessful, the scan tool will display one of the following error messages: PROGRAMMING NOT ATTEMPTED - The scan tool attempts to read the programmed key status and there are no keys programmed into SKREEM memory. - PROGRAMMING KEY FAILED (POSSIBLE USED KEY FROM WRONG VEHICLE) - SKREEM is unable to program an ignition key transponder due to one of the following: - The ignition key transponder is ineffective. - The ignition key transponder is or has been already programmed to another vehicle. - 8 KEYS ALREADY LEARNED, PROGRAMMING NOT DONE - The SKREEM transponder ID memory is full. - LEARNED KEY IN IGNITION - The ID for the ignition key transponder currently in the ignition lock cylinder is already programmed into SKREEM memory. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way Memory Positioning Module: Diagrams Memory Seat Module C1 (Left Seat) 14 Way Connector C1 - (LEFT SEAT) 14 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 9095 Memory Positioning Module: Diagrams Memory Seat Module C2 (Left Seat) 6 Way Connector C2 - (LEFT SEAT) 6 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 9096 Memory Positioning Module: Diagrams Memory Seat Module C3 (Left Seat) 14 Way Connector C3 - (LEFT SEAT) 14 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 9097 Memory Positioning Module: Diagrams Memory Seat Module C4 (Left Seat) 6 Way Connector C4 - (LEFT SEAT) 6 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 9098 Memory Positioning Module: Diagrams Memory Seat Module C5 (Adjustable Pedals) 6 Way Connector C5 (ADJUSTABLE PEDALS) - 6 WAY MODULE-SEAT MEMORY (ADJUSTABLE PEDALS) - 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Description and Operation > Memory Seat Module - Description Memory Positioning Module: Description and Operation Memory Seat Module - Description DESCRIPTION NOTE: The scan tool standardization process must be performed on the Memory Seat Module (MSM) any time a new module is installed or the existing module is reflashed. The Memory Seat Module (MSM) is located underneath the driver seat, towards the front and on the outboard side. It is used in conjunction with the other modules in the memory system See: Memory Seat Module - Operation to recall the seat to one of two preset seat functional adjustments (horizontal, vertical, and recliner). The switch for the memory seat programming and selection mounts on the driver door trim panel. The MSM also controls the adjustable pedals, both for the memory and manual functionality. The adjustable accelerator and brake pedals are available on SLT and Limited models. On Limited, their positioning can be stored for recall by the memory system, allowing for two drivers to have unique, pre-programmed settings. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Description and Operation > Memory Seat Module - Description > Page 9101 Memory Positioning Module: Description and Operation Memory Seat Module - Operation OPERATION POWER/MEMORY SEAT The memory seat module receives input from the 8-way power seat switch, the driver seat position sensors, adjustable pedal control circuits (switch, sensor, and motor), and the data bus circuit. The memory switch, is wired to the memory mirror module which sends the message over the data bus. The memory seat module performs the following functions: - Positions the driver seat (vertical, horizontal, and recliner positions) and adjustable pedals. - Sends the memory save or recall (#1 or #2) command over the data bus circuit to the memory mirror modules, HVAC, and radio. - Provides for "linking" the key FOBs to memory. - Provides for the easy entry/exit feature. - Provides the tilt mirrors in reverse feature When a memory button is pressed (#1 or #2) on the memory switch, the driver door memory mirror module sends a recall message to the memory seat module (MSM). Then the MSM will position the driver seat and adjustable pedals to its preprogrammed location/setting. When the Remote Keyless Entry (RKE) Transmitter button is pressed, depending on which transmitter (#1 or #2), the SKREEM (RKE Receiver) sends the recall request and FOB number (#1 or #2) data message. This RKE transmitter function depends on if the MSM is programmed to trigger the recall (linked FOBs). A memory setting is saved by pressing the "set" button, then pressing either the memory "1" or "2" button within 5 seconds of pressing the "set" button. A memory setting is recalled by pressing either the memory "1" or "2" button, or by pressing the unlock button on a "linked" Remote Keyless Entry (RKE) transmitter. For driver safety, memorized settings can not be recalled if the transmission is in any position other than park or the seat belt is latched. A key FOB is "linked" to a memory setting by pressing the "set" button and then pressing either the memory "1" or "2" button within 5 seconds of pressing the set button, then by pressing the "lock" button on the selected key FOB. The memory system "Easy Entry and /Exit" feature provides the driver with more room to enter or exit the vehicle. The Easy Entry and Exit feature is disabled when the vehicle leaves the factory. An authorized dealer can enable this feature. When the seat is in a memorized position, it will move rearward 55 millimeters or to the end of its travel, whichever occurs first, when the key is removed from the ignition switch lock cylinder. The seat will return to the memory position when the driver turns the vehicle's ignition switch out of the LOCK position. The memory system "learns" the seat and adjustable pedal motor maximum end positions when the motor reaches the limit of travel in any direction and stalls. Subsequently, movement will stop just short of that position to avoid extra stress on the motors and mechanisms. If the system learned a maximum position as a result of an obstruction, as for instance if a large object was placed on the floor behind the seat, the system can relearn the "true" maximum position through manually operating the power seat after the obstruction is removed. NOTE: It is normal for the power accessories contained in the memory system to stop at the maximum "learned" position and then continue to the "true" maximum position when the control switch is released and then applied in the same direction a second time. Certain functions and features of the memory system rely upon resources shared with other electronic modules in the vehicle over the Controller Area Network (CAN) bus. The CAN bus allows the sharing of sensor information. This helps to reduce wire harness complexity, internal controller hardware, and component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. For diagnosis of these electronic modules or of the CAN bus, the use of a scan tool and the proper diagnostic information are needed. The tilt mirrors in reverse feature provides for tilting the sideview (outside) mirrors down a predetermined angle, providing a better view of the ground next to the rear portion of the vehicle. The tilt mirrors in reverse feature is disabled when the vehicle leaves the factory. An authorized dealer can enable this feature. Operation of the tilt mirrors is as follows: - Sideview mirrors will tilt down when the vehicle transmission is shifted into Reverse. - Sideview mirrors will return to the original position when the vehicle transmission is shifted out of Reverse. ADJUSTABLE PEDALS The pedals swing on a large arc, the radius and angle of which were selected on the basis of ergonomic studies, that puts them in the proper position for use by the smaller driver - higher and angled upward as well as rearward. Powered by the small electric motor driving a gear train at each pedal, adjustment is precise, quiet, and smooth throughout the range. A paddle-type switch on the instrument panel to the left of the steering column actuates the electric motor-driven mechanism through the memory seat module (MSM). Pushing up the paddle brings the pedals closer and vice versa. Movement Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Description and Operation > Memory Seat Module - Description > Page 9102 stops when the switch is released. MSM logic prevents pedal adjustment when the automatic speed control (cruise control) is set (controlling speed), and when the transmission is in reverse. This feature protects against a loss of reference position when neither foot is on the pedal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Description and Operation > Page 9103 Memory Positioning Module: Testing and Inspection MEMORY SEAT MODULE Any diagnosis of the memory seat system/module should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Module - Removal Memory Positioning Module: Service and Repair Memory Seat Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver seat cushion/cover (2) See: Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 3. Unsnap the memory seat module (4) from the side brackets. 4. Pivot the module upward and disconnect the electrical connectors (1). 5. Pull the module rearward to remove it from the front of the seat frame (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Module - Removal > Page 9106 Memory Positioning Module: Service and Repair Memory Seat Module - Installation INSTALLATION 1. Place the module (4) into position making sure the front snaps into the seat frame (3). 2. Connect the memory seat module harness connectors (1). 3. Pivot the module (4) downward and snap it into place in the side brackets. 4. Install the driver seat cushion/cover (2) See: Seats/Seat Cover/Service and Repair/Seat Cushion Cover - Installation. 5. Connect the battery negative cable. 6. Using an appropriate scan tool go to the MSM miscellaneous functions and perform the standardization routine. 7. Verify system and vehicle operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Pedal Positioning Relay > Component Information > Locations Pedal Positioning Relay: Locations Adjustable Pedals Relay is located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Pedal Positioning Relay > Component Information > Locations > Page 9110 Pedal Positioning Relay: Diagrams Connector (IN IPM) RELAY-ADJUSTABLE PEDALS (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Power Liftgate Module Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Power Liftgate Module > Page 9115 Power Trunk / Liftgate Control Module: Locations Power Liftgate Module C2 (Body) 22 Way Connector C2 - (BODY) 22 WAY MODULE-POWER LIFTGATE - (BODY) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Locations > Power Liftgate Module > Page 9116 Power Trunk / Liftgate Control Module: Locations Power Liftgate Module C3 (Body) 2 Way Connector C3 - (BODY) 2 WAY MODULE-POWER LIFTGATE - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Diagrams > Power Liftgate Module C1 (Body) 12 Way Power Trunk / Liftgate Control Module: Diagrams Power Liftgate Module C1 (Body) 12 Way Connector C1 - (BODY) 12 WAY MODULE-POWER LIFTGATE - (BODY) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Diagrams > Power Liftgate Module C1 (Body) 12 Way > Page 9119 Power Trunk / Liftgate Control Module: Diagrams Power Liftgate Module C2 (Body) 22 Way Connector C2 - (BODY) 22 WAY MODULE-POWER LIFTGATE - (BODY) 22 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Diagrams > Power Liftgate Module C1 (Body) 12 Way > Page 9120 Power Trunk / Liftgate Control Module: Diagrams Power Liftgate Module C3 (Body) 2 Way Connector C3 - (BODY) 2 WAY MODULE-POWER LIFTGATE - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Description and Operation > Power Liftgate Control Module - Description Power Trunk / Liftgate Control Module: Description and Operation Power Liftgate Control Module Description DESCRIPTION Vehicles equipped with a power liftgate system utilize a power liftgate control module (4). This module is located on the left side of the vehicle behind the C-pillar below the quarter glass The power liftgate control module receives and monitors logic inputs from all the power liftgate system switches. This module also contains the software technology to detect liftgate obstructions and stop or reverse the door accordingly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Description and Operation > Power Liftgate Control Module - Description > Page 9123 Power Trunk / Liftgate Control Module: Description and Operation Power Liftgate Control Module Operation OPERATION The power liftgate control module contains the electronic circuitry and software used to control the sequence of events for the power liftgate system. This module communicates on the Controller Area Network (CAN) to monitor many different inputs and outputs such as door lock status, transmission gear selector position and vehicle speed. The power liftgate open/close command can be initiated by either one press of the power liftgate overhead console switch or two presses of the key fob power liftgate switch. The overhead switch is hardwired to the power liftgate control module. The key fob, sends a signal out on the Controller Area Network (CAN) Data Bus circuit. This signal is detected at the Power Liftgate Control Module. The power liftgate control module then interprets the information to confirm safety requirements are met before applying power to the power liftgate drive unit to start a power cycle. During a power liftgate open or close cycle, if the power liftgate control module detects sufficient resistance to liftgate travel, such as an obstruction in the liftgate's path. The control module will immediately stop liftgate movement and reverse the direction of travel to the full open or closed position. The power liftgate control module has the ability to relearn. After 8 miles have been recorded on the odometer, anytime the liftgate is fully opened and fully closed using the automatic system, the module will learn from its cycle. If a replacement power liftgate component is installed or a liftgate adjustment is made, the module will relearn the effort and time required to open or close the liftgate. This learn cycle can be performed with a Diagnostic Scan Tool or with a complete cycle of the liftgate, using either one of the command switches. See: Doors, Hood and Trunk/Trunk / Liftgate/Testing and Inspection/Programming and Relearning for detailed instructions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Description and Operation > Page 9124 Power Trunk / Liftgate Control Module: Testing and Inspection POWER LIFTGATE CONTROL MODULE Any diagnosis of the Power Liftgate System should begin with the use of a diagnostic scan tool. For information on the use of the scan tool, refer to the appropriate Diagnostic Procedures Information. Inspect the related wiring harness connectors for broken, bent, pushed out, or corroded terminals. Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. Before any testing of the power liftgate system is attempted, the battery should be fully-charged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Service and Repair > Power Liftgate Control Module - Removal Power Trunk / Liftgate Control Module: Service and Repair Power Liftgate Control Module Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the left quarter trim panel from the vehicle, See: Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. 3. Disconnect the wire harness connectors (2) from the power liftgate control module (4). 4. Using molding remover C-4829A gently pry the clip (1) out of the retaining hole holding the power liftgate control module (4) to the quarter panel. 5. Tilt the top of the module (4) away from the quarter panel and lift upward to disengage the mounting tab from the locating slot (3). 6. Remove the power liftgate control module (4) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Trunk / Liftgate Control Module > Component Information > Service and Repair > Power Liftgate Control Module - Removal > Page 9127 Power Trunk / Liftgate Control Module: Service and Repair Power Liftgate Control Module Installation INSTALLATION 1. Position the power liftgate control module (4) into the vehicle. 2. Insert the mounting tab into the locating slot (3) on the quarter panel. 3. Tilt the top of the module (4) toward the quarter panel and firmly press the clip (1) into the retaining hole on the quarter panel. 4. Connect the wire harness connectors (2) to the power liftgate control module (4). 5. Install the left quarter trim panel, See: Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel Installation. 6. Connect the battery negative cable. 7. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes. 8. Perform the power liftgate learn cycle, See: Doors, Hood and Trunk/Trunk / Liftgate/Testing and Inspection/Programming and Relearning. 9. Verify power liftgate system operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Locations > Page 9131 Seat Heater Control Module: Diagrams Connector - (BODY) 6 WAY MODULE-HEATED SEAT - (BODY) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description Seat Heater Control Module: Description and Operation Heated Seat Module - Description DESCRIPTION The heated seat module (2) is located behind the right rear D-pillar trim (1). The heated seat module has a single electrical connector (3). The heated seat module is an microprocessor designed to use CAN bus messages from the cluster Cabin Compartment Node (CCN) to operate the heated seat elements in both front seats. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description > Page 9134 Seat Heater Control Module: Description and Operation Heated Seat Module - Operation OPERATION The heated seat module operates on fused battery current received from the ignition switch. The module is grounded at all times through a ground lug on the right rear D-pillar. Inputs to the module include CAN bus messages and standard hardwired 12volt power and ground. In response to those inputs the heated seat module controls the battery current to the heated seat elements. When a heated seat switch CAN bus signal is received by the heated seat module, the module energizes the selected heated seat element. The Low heat set point is about 38°C (100.4°F), and the High heat set point is about 42°C (107.6°F). If the heated seat module detects a heated seat element OPEN or SHORT circuit, it will record and store an diagnostic trouble code (DTC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Description and Operation > Page 9135 Seat Heater Control Module: Testing and Inspection HEATED SEAT MODULE 1. Test the appropriate heated seat element See: Seats/Seat Heater/Testing and Inspection. 2. Test the appropriate heated seat switch. 3. Using a voltmeter, backprobe the heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12v should be present. If OK go to 4 , if Not, repair the open or shorted voltage supply circuit as required. 4. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK test the Cabin compartment Node (CCN) cluster using a scan tool for proper heated seat system function. If Not OK, Repair the open or shorted ground circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal Seat Heater Control Module: Service and Repair Heated Seat Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the liftgate and remove the upper D-pillar trim from the vehicle. See: Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Removal. 3. Remove the lower D-pillar trim from the vehicle. See: Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Removal . 4. Disconnect the wire harness connector from the back of the heated seat module (2). 5. Unsnap the heated seat module (2) from the D-pillar (1). 6. Remove the heated seat module (2) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal > Page 9138 Seat Heater Control Module: Service and Repair Heated Seat Module - Installation INSTALLATION 1. Install the heated seat module on the D-pillar (1). 2. Connect the wire harness connector (3) to the heated seat module (2). 3. Reconnect the negative battery cable. 4. Check for proper heated seat system operation. 5. Install the upper and lower D-pillar trim to the vehicle. See: Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Installation. 6. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Locations Trailer Towing Relay: Locations Trailer Tow Left and Right Relays are located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Relay-Trailer Tow-Left Trailer Towing Relay: Diagrams Relay-Trailer Tow-Left Connector (IN IPM) RELAY-TRAILER TOW-LEFT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Diagrams > Relay-Trailer Tow-Left > Page 9144 Trailer Towing Relay: Diagrams Relay-Trailer Tow-Right Connector (IN IPM) RELAY-TRAILER TOW-RIGHT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description Trailer Towing Relay: Description and Operation Trailer Tow Relay - Description DESCRIPTION Vehicles equipped with an optional factory-installed trailer towing package have two trailer tow relays, one for the trailer right turn and brake lamps and the other for the trailer left turn and brake lamps. The trailer tow relays are conventional International Standards Organization (ISO) micro relays. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. Each relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The trailer tow relays are located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. A trailer tow relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trailer Towing Relay > Component Information > Description and Operation > Trailer Tow Relay - Description > Page 9147 Trailer Towing Relay: Description and Operation Trailer Tow Relay - Operation OPERATION The trailer tow relays are electromechanical switches that use a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to trailer brake and turn signal lamps. Within each relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the trailer tow relays include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a right or left trailer tow turn relay control circuit. The FCM controls trailer brake and turn lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the trailer lamps through a right or left trailer tow turn relay output circuit and provides battery voltage to the right or left trailer brake and turn lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The trailer tow relays as well as the hard wired inputs and outputs of the relays may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Luggage Rack > Component Information > Description and Operation Luggage Rack: Description and Operation DESCRIPTION LUGGAGE RACK Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade - Removal Sun Shade: Service and Repair Sunroof Sunshade - Removal REMOVAL 1. Remove the water channel. See: Sunroof / Moonroof Drain/Service and Repair/Sunroof Drain Channel - Removal 2. Cycle sunroof motor to the open position. 3. Move sunshade towards the closed position stopping three to four inches from the closed position. 4. Depress the spring feet clips (1) in the cross car direction on one side of the sunshade by applying a side-load to the shade while pulling up at the front centerline of the sunshade. This will cause one spring feet clip (1) to pop out of the track. 5. Remove the other front foot by rotating the shade (1) out and the foot resting on the top of the sunroof frame (2). 6. Pull the shade farther forward in the vehicle and repeat the previous step to remove the rear spring feet. 7. Remove the sunshade (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunroof Sunshade - Removal > Page 9157 Sun Shade: Service and Repair Sunroof Sunshade - Installation INSTALLATION 1. Place one side of the sunshade (1) spring feet clips into the top track U-frame (2). 2. Depress the both releasing clips (1) on the other side to allow them to go into the top track of the U-frame (2). 3. Move sunshade to the open position. 4. Verify that the sunshade moves back and forth properly. 5. Cycle sunroof towards the closed position. 6. Position the sunshade so that the handle is in the center of the opening. 7. Install the water channel. See: Sunroof / Moonroof Drain/Service and Repair/Sunroof Drain Channel - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 9161 Sunroof / Moonroof Motor: Diagrams Connector - (SUNROOF) 12 WAY MOTOR-SUNROOF - (SUNROOF) 12 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 9162 Sunroof / Moonroof Motor: Testing and Inspection INITIALIZATION 1. To initialize the motor, connect power to the sunroof. 2. Press the close-button until the glass panel has reached the full closed position.There will be a slight "kick" of the glass panel when initialization occurs if the glass panel starts in the full closed position.The "kick" is accompanied by a soft tick noise. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 9163 Sunroof / Moonroof Motor: Adjustments ADJUSTMENT CAUTION: There is no adjustment available for a normally operating sunroof. This procedure is used to set sunroof motor to sunroof assembly timing before the motor is installed in the assembly. 1. Manually push the sunroof guide assembly (4) to the full forward position until it is locked into position. This is verified by attempting to push the guide assembly rearward. NOTE: The guide rail (2) will be raised above the U-frame assembly (4) when in the lock position. 2. Remove the sunroof glass See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass Removal. 3. Manually move the guide pivot (3) inside the guide cam slot until it is centered between the etched timing marks (1) on both rails on both the left hand and right hand side rails. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 9164 4. Verify that the white marking is visible in the new motor window (1). If the mark is not visible, connect a power source to the motor and cycle the 'close' button until the motor is in the closed position (indicated by the white mark in the window). 5. Install the sunroof motor and verify proper sunroof operation See: Service and Repair/Sunroof Motor - Installation. 6. Install the sunroof glass, leaving the retaining bolts loose. 7. Install the sunroof assembly into the vehicle See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass - Installation. 8. Flush the sunroof glass into the vehicle roof opening and check sunroof glass alignment See: Sunroof / Moonroof Panel/Adjustments. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > Sunroof Motor - Installation Sunroof / Moonroof Motor: Service and Repair Sunroof Motor - Installation INSTALLATION CAUTION: The sunroof motor must be timed with the sunroof assembly. Failure to do so will result in improper sunroof operation and possible leakage or damage to the assembly. 1. Assure proper sunroof motor timing before installation See: Adjustments. 2. Position the sunroof motor (9) to the sunroof assembly, install the retaining screws (10) and tighten to 4 Nm (40 in. lbs.). 3. Connect the timed sunroof assembly to a power source and initialize. See: Testing and Inspection. 4. Assure proper operation before installing the sunroof assembly into the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Sunroof Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations > Sunroof Switch > Page 9171 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Sunroof Switch (Headliner) 4 Way Sunroof / Moonroof Switch: Diagrams Sunroof Switch (Headliner) 4 Way Connector - (HEADLINER) 4 WAY SWITCH-SUNROOF - (HEADLINER) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Sunroof Switch (Headliner) 4 Way > Page 9174 Sunroof / Moonroof Switch: Diagrams Sunroof/Power Liftgate Switch (Headliner) 6 Way Connector - (HEADLINER) 6 WAY SWITCH-SUNROOF/LIFTGATE PLG - (HEADLINER) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Power Top Switch - Removal Sunroof / Moonroof Switch: Service and Repair Power Top Switch - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Separate the overhead console from the headliner, by carefully pulling down on the front portion, toward the windshield, to release the retaining clips. 3. Release the sunroof switch retaining tab (2), disconnect the electrical connector (1) and remove the switch from the console. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Power Top Switch - Removal > Page 9177 Sunroof / Moonroof Switch: Service and Repair Power Top Switch - Installation INSTALLATION 1. Position the switch (2) against the overhead console (1) and push the switch to seat properly in retaining clip (3). 2. Install the overhead console and seat the retaining clips (4) fully. 3. Connect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Wind Deflector - Removal Sunroof / Moonroof Windguard: Service and Repair Wind Deflector - Removal REMOVAL Including front hinges: 1. Fully open sunroof glass panel. 2. Remove sunroof assembly (1). See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass - Removal. 3. Depress the front deflector retaining tabs (2). 4. Using a small flat bladed tool (2) or equivalent, release the both hinges (1) from the U-frame track. Right side hinge shown, left similar. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Wind Deflector - Removal > Page 9182 5. Rotate the hinge feet (1) up and out of the U-frame (2) and remove wind deflector. Right side hinge shown, left similar. Without front hinges: 1. Using a small flat bladed tool (2) or equivalent, release the both hinges (1) from the U-frame track. Right side hinge shown, left similar. 2. Using a small flat bladed tool or equivalent, release the inner locking tab (2) portion of the hinges from the U-frame tracks (3) and separate the hinges (1) from the track. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Wind Deflector - Removal > Page 9183 NOTE: Placing a small rolled up piece of paper or equivalent, between the hinge and the sunroof opening may aid installation of the wind deflector. 3. Using needle-nose pliers (3) squeeze the retaining tabs on the forward hinges (2) and separate the wind deflector (1) from the hinges. 4. Slide the wind deflector assembly (1) rearward to the back of the roof opening (2) and remove. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Wind Deflector - Removal > Page 9184 Sunroof / Moonroof Windguard: Service and Repair Wind Deflector - Installation INSTALLATION Including front hinges: 1. Position the spring arms down into the trough. 2. Place wind deflector arms in upward position engage the wind deflector blade into the U-frame. 3. Seat the retaining clips (2) fully. 4. Position the wind deflector hinges (1) into the U-frame at the notch (2) and secure down into the channel fully. Right side hinge shown, left side similar. 5. Verify wind deflector operation. 6. Install the sun roof assembly See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass - Installation. Without front hinges: Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Windguard > Component Information > Service and Repair > Wind Deflector - Removal > Page 9185 1. Position wind deflector assembly (1) into the roof opening (2) and slide forward to the mounting point in the U-frame. 2. Position the wind deflector hinges (1) into the U-frame at the notch (2) and secure down into the channel fully. Right side hinge shown, left side similar. NOTE: Placing a small rolled up piece of paper or equivalent, between the hinge and the sunroof opening may aid installation of the wind deflector. 3. Position the front of the wind deflector over the front hinges and seat down onto the retaining clips fully. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Channel - Removal Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Channel - Removal REMOVAL 1. Remove glass panel (2). See: Sunroof / Moonroof Panel/Service and Repair/Sunroof Glass Removal 2. Remove the retaining screws (4). 3. Carefully slide water channel (1) forward to release tabs from U-frame (12) and remove from vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Channel - Removal > Page 9190 Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Channel - Installation INSTALLATION 1. Carefully place water channel (1) onto U-frame (12) and slide it rearward to lock tabs. 2. Install the water channel attaching screws (4) driver's side first then passenger side. 3. Tighten the screws to 1.5 Nm (12 in. lbs.). 4. Position glass panel (1) on to mechanism lift arms. 5. Start the glass attaching screws (3), and hand tighten. 6. Adjust sunroof glass See: Sunroof / Moonroof Panel/Adjustments. 7. Verify sunroof operation and alignment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Channel - Removal > Page 9191 Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Tube - Removal REMOVAL FRONT HOSES 1. Move glass panel to the fully closed position. 2. Disconnect negative battery cable. 3. Remove headliner See: Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Removal. 4. Disconnect the drain hose from the sunroof housing (1). 5. Drain any liquid from hose connection. 6. Remove tube (2), as necessary. REAR HOUSING HOSE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Channel - Removal > Page 9192 1. Move glass panel to the fully closed position. 2. Disconnect negative battery cable. 3. Remove headliner See: Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Removal. 4. Disconnect the drain hose from the sunroof housing (1). 5. Drain any liquid from hose connection, if necessary. 6. Release the push pin fasteners (1) and remove the tube (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Channel - Removal > Page 9193 Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Tube - Installation INSTALLATION FRONT HOSES 1. Connect the new drain hose (2) to the sunroof housing (1) and test drainage. 2. Install headliner See: Interior Moulding / Trim/Headliner/Service and Repair/Headliner - Installation. 3. Verify sunroof operation and alignment. REAR HOUSING HOSE 1. Install the rear hose (2) and seat the push pin fasteners (1) fully. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Channel - Removal > Page 9194 2. Connect the new drain hose (1) to the sunroof housing and test drainage. 3. Install the quarter trim panels. See: Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel Installation 4. Install headlinerSee: Interior Moulding / Trim/Headliner/Service and Repair/Headliner Installation. 5. Connect the control switch wire connector and install control switch. 6. Verify sunroof operation and alignment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Sunroof Trim Lace - Removal Sunroof / Moonroof Interior Trim Panel: Service and Repair Sunroof Trim Lace - Removal REMOVAL 1. Remove trim lace (13) by holding one end of the trim lace at the butt joint and pulling horizontally into the opening until lace is completely loose from the headliner/sunroof joint. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Interior Trim Panel > Component Information > Service and Repair > Sunroof Trim Lace - Removal > Page 9199 Sunroof / Moonroof Interior Trim Panel: Service and Repair Sunroof Trim Lace - Installation INSTALLATION 1. Place butt joint of trim lace into position starting at the rear of the opening at the butt joint notch (14) in the U-frame. 2. Push lace into position. 3. Ensure that the corner radii is fully engaged. 4. Once the original trim lace is attached to sunroof module using a trim stick C-4755 or equivalent, begin tucking the headliner under the lip on the trim lace working all the way around the opening. When installing a new trim lace, begin tucking the headliner under the lip as the tear cord is removed working all the way around the opening. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments Sunroof / Moonroof Panel: Adjustments ADJUSTMENTS 1. Move the sunshade (5) rearward to the open position. 2. Move the sunroof glass panel (2) to the fully closed position. 3. Loosen all glass attachment screws on both sides of the module such that the glass panel is adjustable in the vertical and fore-aft directions. 4. Cycle the sunroof open, closed, vent and closed again. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Page 9203 5. Standing outside the vehicle (one side at a time with one hand supporting the front corner of the glass panel) lift the front glass panel corner (3) until it is between flush and slightly under flush 0.00 to - 1.75 (.068 inches) mm with the front roof corner (2). User your free hand to snug up the glass bolt with sufficient force (finger tight) that the weight of the glass panel corner is supported. Repeat this process on the other side of the vehicle. 6. Move to the rear of the sunroof glass panel. Standing outside of the vehicle (one side at a time with one hand supporting the rear corner of the glass panel) lift the rear glass panel corner (3) until it is between flush and slightly over flush 0.00 to +1.75mm (.068 inches) with the rear roof corner (2). Use your free hand to snug up the glass bolt with sufficient force (finger tight) that the weight of the glass panel corner is supported. Repeat this process on the other side of the vehicle. 7. Check the flushness of the glass panel in the corners with a business card (1) (or other straight edged tool that won't scratch the glass or roof) held at a 45 degree angle to the vehicle's for/aft centerline. The preferred glass panel placement for blockage of wirer/air leaks is flush at all the corners. If this is not possible, adjust the glass panel's vertical placement within the tolerance ranges described above towards the flush position. 8. If the glass panel's vertical position needs to be adjusted, loosen the bolt at the corner and make the necessary adjustments. Tighten the bolt before moving onto the next corner. 9. Once the proper glass position has been achieved, tighten the six glass panel attaching screws to 3.5 Nm (31 in. lbs.). 10. Check for proper fit. If not OK, repeat glass panel adjustment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Sunroof Glass - Removal Sunroof / Moonroof Panel: Service and Repair Sunroof Glass - Removal REMOVAL 1. Move the glass panel (2) to the vent position. 2. Slide sunshade (5) rearward to the open position. 3. Remove the glass panel screws (3). 4. Lift off glass panel (2) and remove from vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Service and Repair > Sunroof Glass - Removal > Page 9206 Sunroof / Moonroof Panel: Service and Repair Sunroof Glass - Installation INSTALLATION 1. Position glass panel (2) on to mechanism lift arms. 2. Start the attaching screws (3). 3. Connect a 12v power supply and move the sunroof to the vent position then to the closed position. 4. Adjust sunroof glass (2) to fit flush with roof line See: Adjustments. 5. Tighten the screws (3). 6. Verify sunroof operation and alignment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way Memory Positioning Module: Diagrams Memory Seat Module C1 (Left Seat) 14 Way Connector C1 - (LEFT SEAT) 14 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 9214 Memory Positioning Module: Diagrams Memory Seat Module C2 (Left Seat) 6 Way Connector C2 - (LEFT SEAT) 6 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 9215 Memory Positioning Module: Diagrams Memory Seat Module C3 (Left Seat) 14 Way Connector C3 - (LEFT SEAT) 14 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 14 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 9216 Memory Positioning Module: Diagrams Memory Seat Module C4 (Left Seat) 6 Way Connector C4 - (LEFT SEAT) 6 WAY MODULE-SEAT MEMORY - (LEFT SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Diagrams > Memory Seat Module C1 (Left Seat) 14 Way > Page 9217 Memory Positioning Module: Diagrams Memory Seat Module C5 (Adjustable Pedals) 6 Way Connector C5 (ADJUSTABLE PEDALS) - 6 WAY MODULE-SEAT MEMORY (ADJUSTABLE PEDALS) - 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Description and Operation > Memory Seat Module - Description Memory Positioning Module: Description and Operation Memory Seat Module - Description DESCRIPTION NOTE: The scan tool standardization process must be performed on the Memory Seat Module (MSM) any time a new module is installed or the existing module is reflashed. The Memory Seat Module (MSM) is located underneath the driver seat, towards the front and on the outboard side. It is used in conjunction with the other modules in the memory system See: Memory Seat Module - Operation to recall the seat to one of two preset seat functional adjustments (horizontal, vertical, and recliner). The switch for the memory seat programming and selection mounts on the driver door trim panel. The MSM also controls the adjustable pedals, both for the memory and manual functionality. The adjustable accelerator and brake pedals are available on SLT and Limited models. On Limited, their positioning can be stored for recall by the memory system, allowing for two drivers to have unique, pre-programmed settings. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Description and Operation > Memory Seat Module - Description > Page 9220 Memory Positioning Module: Description and Operation Memory Seat Module - Operation OPERATION POWER/MEMORY SEAT The memory seat module receives input from the 8-way power seat switch, the driver seat position sensors, adjustable pedal control circuits (switch, sensor, and motor), and the data bus circuit. The memory switch, is wired to the memory mirror module which sends the message over the data bus. The memory seat module performs the following functions: - Positions the driver seat (vertical, horizontal, and recliner positions) and adjustable pedals. - Sends the memory save or recall (#1 or #2) command over the data bus circuit to the memory mirror modules, HVAC, and radio. - Provides for "linking" the key FOBs to memory. - Provides for the easy entry/exit feature. - Provides the tilt mirrors in reverse feature When a memory button is pressed (#1 or #2) on the memory switch, the driver door memory mirror module sends a recall message to the memory seat module (MSM). Then the MSM will position the driver seat and adjustable pedals to its preprogrammed location/setting. When the Remote Keyless Entry (RKE) Transmitter button is pressed, depending on which transmitter (#1 or #2), the SKREEM (RKE Receiver) sends the recall request and FOB number (#1 or #2) data message. This RKE transmitter function depends on if the MSM is programmed to trigger the recall (linked FOBs). A memory setting is saved by pressing the "set" button, then pressing either the memory "1" or "2" button within 5 seconds of pressing the "set" button. A memory setting is recalled by pressing either the memory "1" or "2" button, or by pressing the unlock button on a "linked" Remote Keyless Entry (RKE) transmitter. For driver safety, memorized settings can not be recalled if the transmission is in any position other than park or the seat belt is latched. A key FOB is "linked" to a memory setting by pressing the "set" button and then pressing either the memory "1" or "2" button within 5 seconds of pressing the set button, then by pressing the "lock" button on the selected key FOB. The memory system "Easy Entry and /Exit" feature provides the driver with more room to enter or exit the vehicle. The Easy Entry and Exit feature is disabled when the vehicle leaves the factory. An authorized dealer can enable this feature. When the seat is in a memorized position, it will move rearward 55 millimeters or to the end of its travel, whichever occurs first, when the key is removed from the ignition switch lock cylinder. The seat will return to the memory position when the driver turns the vehicle's ignition switch out of the LOCK position. The memory system "learns" the seat and adjustable pedal motor maximum end positions when the motor reaches the limit of travel in any direction and stalls. Subsequently, movement will stop just short of that position to avoid extra stress on the motors and mechanisms. If the system learned a maximum position as a result of an obstruction, as for instance if a large object was placed on the floor behind the seat, the system can relearn the "true" maximum position through manually operating the power seat after the obstruction is removed. NOTE: It is normal for the power accessories contained in the memory system to stop at the maximum "learned" position and then continue to the "true" maximum position when the control switch is released and then applied in the same direction a second time. Certain functions and features of the memory system rely upon resources shared with other electronic modules in the vehicle over the Controller Area Network (CAN) bus. The CAN bus allows the sharing of sensor information. This helps to reduce wire harness complexity, internal controller hardware, and component sensor current loads. At the same time, this system provides increased reliability, enhanced diagnostics, and allows the addition of many new feature capabilities. For diagnosis of these electronic modules or of the CAN bus, the use of a scan tool and the proper diagnostic information are needed. The tilt mirrors in reverse feature provides for tilting the sideview (outside) mirrors down a predetermined angle, providing a better view of the ground next to the rear portion of the vehicle. The tilt mirrors in reverse feature is disabled when the vehicle leaves the factory. An authorized dealer can enable this feature. Operation of the tilt mirrors is as follows: - Sideview mirrors will tilt down when the vehicle transmission is shifted into Reverse. - Sideview mirrors will return to the original position when the vehicle transmission is shifted out of Reverse. ADJUSTABLE PEDALS The pedals swing on a large arc, the radius and angle of which were selected on the basis of ergonomic studies, that puts them in the proper position for use by the smaller driver - higher and angled upward as well as rearward. Powered by the small electric motor driving a gear train at each pedal, adjustment is precise, quiet, and smooth throughout the range. A paddle-type switch on the instrument panel to the left of the steering column actuates the electric motor-driven mechanism through the memory seat module (MSM). Pushing up the paddle brings the pedals closer and vice versa. Movement Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Description and Operation > Memory Seat Module - Description > Page 9221 stops when the switch is released. MSM logic prevents pedal adjustment when the automatic speed control (cruise control) is set (controlling speed), and when the transmission is in reverse. This feature protects against a loss of reference position when neither foot is on the pedal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Description and Operation > Page 9222 Memory Positioning Module: Testing and Inspection MEMORY SEAT MODULE Any diagnosis of the memory seat system/module should begin with, the use of a scan tool and the appropriate diagnostic service information. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Module - Removal Memory Positioning Module: Service and Repair Memory Seat Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the driver seat cushion/cover (2) See: Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 3. Unsnap the memory seat module (4) from the side brackets. 4. Pivot the module upward and disconnect the electrical connectors (1). 5. Pull the module rearward to remove it from the front of the seat frame (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Memory Positioning Module > Component Information > Service and Repair > Memory Seat Module - Removal > Page 9225 Memory Positioning Module: Service and Repair Memory Seat Module - Installation INSTALLATION 1. Place the module (4) into position making sure the front snaps into the seat frame (3). 2. Connect the memory seat module harness connectors (1). 3. Pivot the module (4) downward and snap it into place in the side brackets. 4. Install the driver seat cushion/cover (2) See: Seat Cover/Service and Repair/Seat Cushion Cover - Installation. 5. Connect the battery negative cable. 6. Using an appropriate scan tool go to the MSM miscellaneous functions and perform the standardization routine. 7. Verify system and vehicle operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component Information > Locations > Page 9229 Seat Memory Switch: Diagrams Connector - (LEFT FRONT DOOR) 6 WAY SWITCH-MEMORY SELECTOR - (LEFT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Driver Seat Horizontal Adjuster Motor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Driver Seat Horizontal Adjuster Motor > Page 9234 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Driver Seat Horizontal Adjuster Motor > Page 9235 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations > Driver Seat Horizontal Adjuster Motor > Page 9236 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Horizontal Adjuster Motor (Driver Seat) 4 Way Power Seat Motor: Diagrams Driver Seat Horizontal Adjuster Motor (Driver Seat) 4 Way Connector - (DRIVER SEAT) 4 WAY MOTOR-SEAT ADJUSTER-DRIVER HORIZONTAL - (DRIVER SEAT) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Horizontal Adjuster Motor (Driver Seat) 4 Way > Page 9239 Power Seat Motor: Diagrams Driver Seat Recliner Adjuster Motor (Except Memory) (Driver Seat) 2 Way Connector (EXCEPT MEMORY) - (DRIVER SEAT) 2 WAY MOTOR-SEAT ADJUSTER-DRIVER RECLINER (EXCEPT MEMORY) - (DRIVER SEAT) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Horizontal Adjuster Motor (Driver Seat) 4 Way > Page 9240 Power Seat Motor: Diagrams Driver Seat Recliner Adjuster Motor (Memory) (Driver Seat) 4 Way Connector (MEMORY) - (DRIVER SEAT) 4 WAY MOTOR-SEAT ADJUSTER-DRIVER RECLINER (MEMORY) - (DRIVER SEAT) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Horizontal Adjuster Motor (Driver Seat) 4 Way > Page 9241 Power Seat Motor: Diagrams Driver Seat Front Vertical Adjuster Motor (Driver Seat) 4 Way Connector - (DRIVER SEAT) 4 WAY MOTOR-SEAT ADJUSTER-FRONT DRIVER VERTICAL - (DRIVER SEAT) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Horizontal Adjuster Motor (Driver Seat) 4 Way > Page 9242 Power Seat Motor: Diagrams Driver Seat Horizontal Adjuster Motor (Driver Seat) 4 Way Connector - (DRIVER SEAT) 4 WAY MOTOR-SEAT ADJUSTER-DRIVER HORIZONTAL - (DRIVER SEAT) 4 WAY Driver Seat Recliner Adjuster Motor (Except Memory) (Driver Seat) 2 Way Connector (EXCEPT MEMORY) - (DRIVER SEAT) 2 WAY MOTOR-SEAT ADJUSTER-DRIVER RECLINER (EXCEPT MEMORY) - (DRIVER SEAT) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Horizontal Adjuster Motor (Driver Seat) 4 Way > Page 9243 Driver Seat Recliner Adjuster Motor (Memory) (Driver Seat) 4 Way Connector (MEMORY) - (DRIVER SEAT) 4 WAY MOTOR-SEAT ADJUSTER-DRIVER RECLINER (MEMORY) - (DRIVER SEAT) 4 WAY Driver Seat Front Vertical Adjuster Motor (Driver Seat) 4 Way Connector - (DRIVER SEAT) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Horizontal Adjuster Motor (Driver Seat) 4 Way > Page 9244 MOTOR-SEAT ADJUSTER-FRONT DRIVER VERTICAL - (DRIVER SEAT) 4 WAY Passenger Seat Horizontal Adjuster Motor (Passenger Seat) 4 Way Connector - (PASSENGER SEAT) 4 WAY MOTOR-SEAT ADJUSTER-PASSENGER HORIZONTAL - (PASSENGER SEAT) 4 WAY Passenger Seat Recliner Adjuster Motor (Passenger Seat) 2 Way Connector - (PASSENGER SEAT) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Driver Seat Horizontal Adjuster Motor (Driver Seat) 4 Way > Page 9245 MOTOR-SEAT ADJUSTER-PASSENGER RECLINER - (PASSENGER SEAT) 2 WAY Driver Seat Rear Vertical Adjuster Motor (Driver Seat) 4 Way Connector - (DRIVER SEAT) 4 WAY MOTOR-SEAT ADJUSTER-REAR DRIVER VERTICAL - (DRIVER SEAT) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Power Seat Motor - Removal Power Seat Motor: Service and Repair Power Seat Motor - Removal REMOVAL WARNING: A seat structure that has seen significant load may have the locking mechanism activated and may exhibit the following symptoms: - Locking pawl (2) loose - Locking pawl (2) engaged into the seat frame side member (1) - Height adjuster only works on outboard side - Broken or missing shear pin (3) If any one or more of these symptoms exist replace the height adjuster assembly. Do not attempt any repairs. Failure to follow these instructions may result in personal injury or death. FRONT TILT MOTOR 1. Disconnect and isolate the battery negative cable. 2. Remove the affected seat with the inoperative motor (1) See: Service and Repair/Seat, Front/Seat - Removal. 3. Remove the seat cushion and pan See: Seat Cover/Service and Repair/Seat Cushion Cover - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Power Seat Motor - Removal > Page 9248 4. Disconnect the motor electrical connector. 5. Remove the fasteners holding the motor to the seat adjuster (1). 6. Remove motor from seat adjuster (2). HEIGHT ADJUST MOTOR WARNING: Use caution when removing the height adjust motor (3) if the motor is inoperative, and the power seat is not in the full up position. The seat adjuster assembly (2) is under load from the height adjust spring and may cause the motor to rotate under pressure when the fasteners are removed. The seat adjuster assembly also may spring upward when the motor is removed. If the height adjust motor is operative, move the power seat to the full up position prior to disconnecting the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Power Seat Motor - Removal > Page 9249 1. Disconnect and isolate the battery negative cable. 2. Remove the affected seat with the inoperative motor (3) See: Service and Repair/Seat, Front/Seat - Removal. 3. Remove the seat cushion and pan See: Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 4. Disconnect the motor electrical connector. 5. Remove the fasteners (1) holding the motor (3) to the seat adjuster (2). 6. Remove screw and washer from the motor shaft. 7. Remove motor (3) from seat adjuster (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Power Seat Motor - Removal > Page 9250 Power Seat Motor: Service and Repair Power Seat Motor - Installation INSTALLATION WARNING: A seat structure that has seen significant load may have the locking mechanism activated and may exhibit the following symptoms: - Locking pawl (2) loose - Locking pawl (2) engaged into the seat frame side member (1) - Height adjuster only works on outboard side - Broken or missing shear pin (3) If any one or more of these symptoms exist replace the height adjuster assembly. Do not attempt any repairs. Failure to follow these instructions may result in personal injury or death. FRONT TILT MOTOR 1. Position motor (1) on seat adjuster (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Power Seat Motor - Removal > Page 9251 2. Install the fasteners (1) holding the motor to the seat adjuster (2). Tighten the screws to 5 Nm (44 in. lbs.). 3. Connect the motor electrical connector. 4. Install the seat cushion See: Seat Cover/Service and Repair/Seat Cushion Cover - Installation. 5. Clip the wire harness to cushion pan. 6. Install the seat assembly See: Service and Repair/Seat, Front/Seat - Installation. 7. Connect the battery negative cable. 8. Verify normal operation of the power seat assembly. HEIGHT ADJUST MOTOR Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Power Seat Motor - Removal > Page 9252 1. Ensure the seat adjuster (2) is in the full up position by pulling upward on the upper adjuster assembly. 2. Position motor (3) on seat adjuster (2). 3. Install the motor shaft screw and washer and tighten until snug. Do not torque screw at this time. 4. Install the screws (1) holding the motor (3) to the seat adjuster (2). It may be necessary to twist the motor slightly to align the fastener holes. 5. Starting with the bottom screw, tighten the motor screws (1) to 9 Nm (80 in. lbs.). 6. Tighten the motor shaft screw and washer to 6.5 Nm (57.5 in. lbs.). 7. Connect the motor electrical connector. 8. Install the seat cushion See: Seat Cover/Service and Repair/Seat Cushion Cover - Installation. 9. Clip the wire harness to cushion pan. 10. Install the seat assembly See: Service and Repair/Seat, Front/Seat - Installation. 11. Connect the battery negative cable. 12. Verify normal operation of the power seat assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Power Seat Motor - Removal > Page 9253 Power Seat Motor: Service and Repair Power Seat Recliner Motor - Removal REMOVAL NOTE: The recliner motor is serviced as part of the seat back frame. Do not attempt to transfer the motor as the service part will come equipped with a new motor installed. 1. Remove the seat back frame assembly See: Seat Cover/Service and Repair/Seat Back Cover Removal. 2. Remove any parts that will need to be installed on new seat back frame assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Driver Seat Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Driver Seat Switch > Page 9258 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Driver Seat Switch (Left Seat) 11 Way Power Seat Switch: Diagrams Driver Seat Switch (Left Seat) 11 Way Connector - (LEFT SEAT) 11 WAY SWITCH-SEAT-DRIVER - (LEFT SEAT) 11 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Driver Seat Switch (Left Seat) 11 Way > Page 9261 Power Seat Switch: Diagrams Passenger Seat Switch (Right Seat) 11 Way Connector - (RIGHT SEAT) 11 WAY SWITCH-SEAT-PASSENGER - (RIGHT SEAT) 11 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and Operation > Power Seat Switch - Description Power Seat Switch: Description and Operation Power Seat Switch - Description DESCRIPTION The driver power seat can be adjusted in eight different ways using the power seat switch. The passenger power seat can be adjusted in four different ways. The power seat switch is located on the lower outboard side of the seat cushion on the seat cushion side shield on all models. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and Operation > Power Seat Switch - Description > Page 9264 Power Seat Switch: Description and Operation Power Seat Switch - Operation OPERATION When a power seat switch is actuated, a battery feed and a ground path are applied through the switch contacts to the power seat adjuster or recliner adjuster motor. The selected adjuster motor operates to move the seat or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. On vehicles equipped with memory system, a resistance signal is sent to the Memory Seat Module (MSM) via the Controller Area Network (CAN) bus circuit, when the driver memory seat switch control knob is actuated. The MSM is responsible for the 12v battery feed and ground path to the power seat adjuster motor. The adjuster motor operates to move the power seat adjuster mechanism through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker may result in motor damage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and Operation > Page 9265 Power Seat Switch: Testing and Inspection POWER SEAT SWITCH DRIVER SEAT WITHOUT MEMORY 1. Disconnect and isolate the negative battery cable. 2. Remove the power seat switch from the power seat. See: Service and Repair/Power Seat Switch - Removal. 3. Use an ohmmeter to test the continuity of the power seat switch. Refer to DRIVER SEAT SWITCH WITHOUT MEMORY TEST table. If not OK, replace the inoperative power seat switch. If switch test OK, See: Testing and Inspection/Component Tests and General Diagnostics. PASSENGER SEAT 1. Disconnect and isolate the negative battery cable. 2. Remove the power seat switch from the power seat. See: Service and Repair/Power Seat Switch - Removal. 3. Use an ohmmeter to test the continuity of the power seat switch. Refer to PASSENGER SEAT SWITCH TEST table. If not OK, replace the inoperative power seat switch. If switch test OK, See: Testing and Inspection/Component Tests and General Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and Operation > Page 9266 DRIVER SEAT WITH MEMORY 1. Disconnect and isolate the negative battery cable. 2. Remove the power seat switch from the power seat. See: Service and Repair/Power Seat Switch - Removal. 3. Use an ohmmeter to test the continuity of the power seat switch. Refer to DRIVER SEAT SWITCH WITH MEMORY table. If not OK, replace the inoperative power seat switch. If switch test OK, See: Testing and Inspection/Component Tests and General Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch - Removal Power Seat Switch: Service and Repair Power Seat Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side panel from the seat and disconnect the electrical harness connector. 3. Using a small flat bladed tool, gently release the four mounting tabs that secure the power seat switch and separate switch from trim panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch - Removal > Page 9269 Power Seat Switch: Service and Repair Power Seat Switch - Installation INSTALLATION 1. Position the power seat switch on the seat cushion side panel. Gently apply pressure to the switch until the four mounting tabs that secure the switch snap into place. 2. Connect the power seat switch electrical connector. 3. Install the seat cushion side panel on the seat. 4. Connect the battery negative cable. 5. Verify normal operation of the power seat assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Adjuster - Removal Seat Back: Service and Repair Front Seat Adjuster - Removal REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions 2. Remove the seat cushion as necessary. See: Seat Cover/Service and Repair/Seat Cushion Cover - Removal Power 1. Remove the seat risers. See: Service and Repair/Seat Riser - Removal 2. Remove the bolts and nuts (2 AND 4) and separate the height adjuster assembly from the length adjuster assembly (3). NOTE: Bolt (4) is a different size from the other three bolts (2). Note the location for proper installation. WARNING: A seat structure that has seen significant load may have the locking mechanism activated and may exhibit the following symptoms: - Locking pawl (2) loose - Locking pawl (2) engaged into the seat frame side member (1) - Height adjuster only works on outboard side - Broken or missing shear pin (3) If any of above symptoms exist, replace the height adjuster assembly. Do not attempt any repairs. Failure to follow these instructions may result in possible serious or fatal injury. If any one or more of these symptoms exist replace the height adjuster assembly. Do not attempt any repairs. Failure to follow these instructions may result in personal injury or death. Manual Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Adjuster - Removal > Page 9274 1. Remove the spring clip. 2. Squeeze the towel bar together and pull the towel bar out of the left and right seat tracks. 3. Remove the bolts (1 and 4), nuts (6) and spacers (2) and separate the side member assembly (3) from the length adjuster assembly (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Adjuster - Removal > Page 9275 Seat Back: Service and Repair Front Seat Adjuster - Installation INSTALLATION Power 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions WARNING: A seat structure that has seen significant load may have the locking mechanism activated and may exhibit the following symptoms: - Locking pawl (2) loose Locking pawl (2) engaged into the seat frame side member (1) - Height adjuster only works on outboard side - Broken or missing shear pin (3) If any of above symptoms exist, replace the height adjuster assembly. Do not attempt any repairs. Failure to follow these instructions may result in possible serious or fatal injury. If any one or more of these symptoms exist replace the height adjuster assembly. Do not attempt any repairs. Failure to follow these instructions may result in personal injury or death. 2. Install the seat risers. See: Service and Repair/Seat Riser - Installation 3. Position the height adjuster assembly (1) onto the length adjuster assembly (3) and install the nuts, bolts and spacers on the inboard side. NOTE: Bolts (2) and (4) are different and need to be installed into the correct positions. 4. Tighten the bolts to 21 Nm (15 ft. lbs.). 5. Install the seat cushion and install the seat. See: Seat Cover/Service and Repair/Seat Cushion Cover - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Adjuster - Removal > Page 9276 Manual 1. Install the seat risers. See: Service and Repair/Seat Riser - Installation 2. Position the side member assembly (3) onto the length adjuster assembly (5) and install the nuts (6), bolts (1 and 4) and spacers (2) on the inboard side. 3. Tighten the bolts to 42 Nm (31 ft. lbs.). 4. Squeeze the towel bar together and insert the ends into the bushings on both tracks. 5. Install the spring clip. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Service and Repair > Front Seat Adjuster - Removal > Page 9277 6. Install the seat cushion and install the seat. See: Seat Cover/Service and Repair/Seat Cushion Cover - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal Seat Cover: Service and Repair Seat Back Cover - Removal Second Row REMOVAL Center 1. Using a trim stick C-4755 or equivalent, remove the cup holder. 2. Using a trim stick C-4755 or equivalent, remove the seat belt bezel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9282 3. Remove the screws and remove the side shields. 4. Remove the bolt and remove the seat belt anchor. 5. Separate the J-straps (1 and 2) and pull cover up over frame. 6. Remove the four seat back bolts and remove the seat back. 7. Remove the seat back cover and foam. Outer 1. Fold the rear seat forward. 2. Remove the side shields. 3. Separate the J-straps (1 and 2) and pull cover up over frame. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9283 4. Remove the four bolts securing the seat back. 5. Remove the head rests and partially remove the seat back cover. 6. Remove the head rest sleeves and remove the cover and cushion. Third Row REMOVAL 1. Remove the seat. See: Service and Repair/Seat, Front/Seat - Removal 2. Remove the headrests. 3. Separate the J-straps (1 and 2) and position the cover/cushion aside. 4. Remove the headrest sleeves and remove the cushion/cover. Front REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9284 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions 2. Remove the front seat. See: Service and Repair/Seat, Front/Seat - Removal 3. Remove the lumbar and recliner handles (1). 4. Remove the screws and remove the side shields (2). 5. Remove the belt buckle. 6. Remove the seat back bolts from both sides. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9285 7. Push in the buttons on both headrest sleeves, pull the headrest up and remove. 8. Separate the J-straps (1 and 2) and pull cover up over frame and remove cushion. 9. Pinch both headrest sleeve ribs from inside the seat back frame with pliers or equivalent. 10. Strike the bottom of the sleeve with a rubber mallet or equivalent, and remove the headrest sleeves. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9286 Seat Cover: Service and Repair Seat Back Cover - Installation Second Row INSTALLATION Center 1. Position the seat back cover and foam over the seat back frame and install the seat back. 2. Install the bolts. 3. Connect the J-straps (1 and 2). 4. Install the seat belt anchor and tighten the bolt to 43 Nm (32 ft. lbs.). 5. Install the side shields. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9287 6. Install the seat belt bezel. 7. Install the cup holder. Outer 1. Position the seat back cover over the seat back frame and install the headrest sleeves. 2. Position the seat back cushion on the frame and position the cover over the cushion. 3. Install the seat back and install the bolts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9288 4. Connect the J-straps (1 and 2). 5. Install the side shields. Third Row INSTALLATION 1. Position the seat back cushion/cover over the seat back frame and connect the J-straps (1 and 2). 2. Install the headrest sleeves. 3. Install the seat. See: Service and Repair/Seat, Front/Seat Installation Front INSTALLATION 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions 2. Position the seat back cover over the seat back frame and install the headrest sleeves. 3. Position the seat back cushion on the frame and position the cover over the cushion. 4. Connect the J-straps (1 and 2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9289 5. Install the seat back bolts and tighten to 40 Nm (30 ft. lbs.). 6. Position the front seat belt buckle lower anchor onto the stud near the rear of the inboard seat cushion frame. Be certain the anti-rotation tab on the anchor is engaged in the clearance hole of the frame. 7. Tighten the nut to 43 Nm (32 ft. lbs.) 8. Install the side shields (2) and install the screws. 9. Install the lumbar and recliner handles (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9290 Seat Cover: Service and Repair Seat Cushion Cover - Removal Front REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions 2. Move the seat to the forward position and disconnect and isolate the batter negative cable. 3. Remove the bolts (2) and the clamps (1) and remove the seat cushion. 4. Disconnect the electrical connector, if equipped. 5. Separate the J-straps (1 and 2) and seat cushion cover and foam. Third Row REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9291 1. Fold seat cushion forward to access the bolts. 2. Remove the bolts (2) and remove the cushion assembly from the vehicle. 3. Separate the J-straps (1 and 2) and remove the cushion/cover from the frame. Second Row REMOVAL Center 1. Fold both outer seats forward. 2. Remove the side shields. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9292 3. Remove the four cushion bolts (2) and seat belt anchor (1) and remove the seat back assembly. 4. Separate the J-straps (1 and 2) and remove cover/cushion from the frame. Outer 1. Remove the seat back. See: Service and Repair/Seat, Front/Seat - Removal. 2. Remove the outboard hinge bolts and remove the connector tube and hinge from the seat. 3. Remove the inboard hinges bolts and hinge. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9293 4. Turn the hinge pin (3) clockwise and disengage from the retaining tabs (2). 5. With pin (1) released from the retaining tabs, tap pin out of the spring (2) and remove. 6. Twist the seat cushion assembly up and out of the outboard hinge (1) and disengage from the inner hinge (2) and remove seat. 7. Remove the seat cushion cover and foam from the seat frame. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9294 Seat Cover: Service and Repair Seat Cushion Cover - Installation Front INSTALLATION 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions 2. Position the cushion cover and foam over the seat pan and connect the J-straps (1 and 2). 3. Position the seat cushion assembly onto the seat frame and install the clamps (1). 4. Connect the wire harness to the seat cushion pan, if equipped. 5. Install the bolts (2) and tighten to 10 Nm (90 in. lbs.). 6. Connect battery negative cable. Third Row INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9295 1. Position the cushion/cover over the frame and connect the J-straps (1 and 2). 2. Install the cushion assembly onto the seat pivot assembly and install the bolts (2). Second Row INSTALLATION Center 1. Connect the J-straps (1 and 2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9296 2. Install the seat belt anchor (1) and four cushion bolts (2). 3. Install the side shields. Outer 1. Install the seat cushion/cover over the seat frame. 2. Position the seat cushion assembly into the vehicle and engage inboard hinge (2). 3. Rotate seat down and engage the outboard hinge (1). 4. Insert the hinge spring (1) and insert the pin (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Service and Repair > Seat Back Cover - Removal > Page 9297 5. Turn the hinge pin (3) and engage the pin into the retaining tabs (2). 6. Install the inboard hinges and bolts. 7. Install the connector tube/outboard hinge assembly into the seat cushion and install the bolts. 8. Install the seat back assembly. See: Service and Repair/Seat, Front/Seat - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Driver Seat Back Heater Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Locations > Driver Seat Back Heater > Page 9302 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Cushion Heater C1 (Component Side) 2 Way Seat Heater: Diagrams Driver Seat Cushion Heater C1 (Component Side) 2 Way Connector C1 (COMPONENT SIDE) - 2 WAY HEATER-CUSHION PAD-DRIVER (COMPONENT SIDE) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Cushion Heater C1 (Component Side) 2 Way > Page 9305 Seat Heater: Diagrams Driver Seat Cushion Heater C1 (Harness Side) 2 Way Connector C1 - (HARNESS SIDE) 2 WAY HEATER-CUSHION PAD-DRIVER - (HARNESS SIDE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Cushion Heater C1 (Component Side) 2 Way > Page 9306 Seat Heater: Diagrams Driver Seat Cushion Heater C2 (Component Side) 2 Way Connector C2 (COMPONENT SIDE) - 2 WAY HEATER-CUSHION PAD-DRIVER (COMPONENT SIDE) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Cushion Heater C1 (Component Side) 2 Way > Page 9307 Seat Heater: Diagrams Passenger Seat Cushion Heater C1 (Component Side) 2 Way Connector C1 (COMPONENT SIDE) - 2 WAY HEATER-CUSHION PAD-PASSENGER (COMPONENT SIDE) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Cushion Heater C1 (Component Side) 2 Way > Page 9308 Seat Heater: Diagrams Driver Seat Cushion Heater C1 (Component Side) 2 Way Connector C1 (COMPONENT SIDE) - 2 WAY HEATER-CUSHION PAD-DRIVER (COMPONENT SIDE) - 2 WAY Driver Seat Cushion Heater C1 (Harness Side) 2 Way Connector C1 - (HARNESS SIDE) 2 WAY HEATER-CUSHION PAD-DRIVER - (HARNESS SIDE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Cushion Heater C1 (Component Side) 2 Way > Page 9309 Driver Seat Cushion Heater C2 (Component Side) 2 Way Connector C2 (COMPONENT SIDE) - 2 WAY HEATER-CUSHION PAD-DRIVER (COMPONENT SIDE) - 2 WAY Passenger Seat Cushion Heater C1 (Component Side) 2 Way Connector C1 (COMPONENT SIDE) - 2 WAY HEATER-CUSHION PAD-PASSENGER (COMPONENT SIDE) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Cushion Heater C1 (Component Side) 2 Way > Page 9310 Passenger Seat Cushion Heater C1 (Harness Side) 2 Way Connector C1 - (HARNESS SIDE) 2 WAY HEATER-CUSHION PAD-PASSENGER - (HARNESS SIDE) 2 WAY Passenger Seat Cushion Heater C2 (Component Side) Connector C2 (COMPONENT SIDE) HEATER-CUSHION PAD-PASSENGER (COMPONENT SIDE) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Cushion Heater C1 (Component Side) 2 Way > Page 9311 Driver Seat Back Heater 2 Way Connector - 2 WAY HEATER-SEAT BACK-DRIVER - 2 WAY Passenger Seat Back Heater 2 Way Connector - 2 WAY HEATER-SEAT BACK-PASSENGER - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Driver Seat Cushion Heater C1 (Component Side) 2 Way > Page 9312 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats - Description Seat Heater: Description and Operation Heated Seats - Description Front Heated Seat System DESCRIPTION Vehicles with the heated seat option can be visually identified by the two heated seat switches located in the center stack of the instrument panel. The heated seat system allows the driver and front seat passenger to select from two different levels of electrical seat heating (HI/LO). The heated seat system for this vehicle includes the following major components, which are described in further detail later: - Heated Seat Elements - Four heated seat elements are used per vehicle. Two heated seat elements are integral to each seat, one in the seat back and the other in the seat cushion. - Heated Seat Module - One heated seat module is used per vehicle. The Heated Seat Module is mounted behind the right rear D-pillar trim panel. This module contains the control logic and software for the front heated seat system. The module also communicates on the CAN data bus network. - Heated Seat Switches - Two heated seat switches are used per vehicle, one for each heated seat. Both switches are mounted in the instrument panel center stack. - Instrument Cluster (CCN) - A Cab Compartment Node (CCN) is part of the instrument cluster on this vehicle. The CCN utilizes integrated software and information carried on the CAN data bus network. The Cab Compartment Node (CCN) serves as the link between the heated seat switches and the heated seat module. Second Row Heated Seat System DESCRIPTION Vehicles with the heated second row seat option can be visually identified by the two heated seat switches (2) located in the rear center floor console (3). The heated seat system allows the second row seat passengers to select from two different levels of electrical seat heating (HI/LO). The heated second row seat system for this vehicle includes the following major components: - Heated Seat Switch/Module - Two heated seat switch/modules are used per vehicle, including two Light-Emitting Diode (LED) indicator lamps for heat level indication. One switch/module for the left and one for the right second row seats. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated second row seat system. The switch/modules are mounted in the front of the rear center floor console. - Heated Seat Elements - Four heated seat elements are used per vehicle, one for each second row seat back and seat cushion. The elements are integral to the second row seat cushion and seat back foam and cannot be removed, once installed at the factory. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats - Description > Page 9315 Seat Heater: Description and Operation Heated Seats - Operation Front Heated Seat System OPERATION The heated seat system operates on battery current received through a fuse in the Integrated Power Module (IPM). Fused ignition switch output (run-acc) circuits are used, so that the heated seat system will only operate when the ignition switch is in the On or Accessory positions. The heated seat system will turn Off automatically whenever the ignition switch is turned to any position except On or Accessory. A Heated Seat Module is used to control the heated seat system. The module responds to heated seat switch messages and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switches are depressed a resistance signal is sent to the Cab Compartment Node (CCN) or instrument cluster. The Cab Compartment Node (CCN) then sends a CAN bus message to the heated seat module, signaling the module to energize the heating element for the selected seat. The Cab Compartment Node (CCN) also turns on the HI and LO LED indicators on each of the heated seat switches. The heated seat module energizes an integral solid-state relay, which supplies battery current to the heating elements. When the pre-programmed duty-cycle has been achieved (approx. 2 hours), the module de-energizes the solid-state relay. The module will continue to cycle the solid-state relay as needed to maintain the temperature set point. No heated seat sensors are used with the heated seat system option. The module will automatically turn off the heating elements if it detects an OPEN or LOW short in the heating element circuit. See the vehicle glove box for more information on the features, use and operation of the heated seat system. Second Row Heated Seat System OPERATION The heated second row seat system operates on battery current received through a fuse in the Integrated Power Module (IPM). Fused ignition switch output (run) circuits are used, so that the heated second row seat system will only operate when the ignition switch is in the On position. The system will turn Off automatically whenever the ignition switch is turned to any position except On. A Heated Seat Switch/Module is used to control the heated second row seat system. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the second row seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after thirty minutes of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue for another thirty minutes and the system will then be automatically turned off. The system will automatically turn off the heating elements if it detects an OPEN or LOW short in the heating element circuit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats - Description > Page 9316 Seat Heater: Description and Operation Heater Pad - Description Front Seats DESCRIPTION Vehicles equipped with the optional heated seat system have two heated seat element located in each front seat. One heating element is used for each seat cushion and another for each seat back. Each of the heated seat element consists of a single length of resistor wire that is routed in a zigzag pattern and captured between the leather trim cover and the seat cushion assembly. Short pigtail wires with connectors are soldered to each end of each resistor wire element grid, which connect all of the element grids to each other in series with the heated seat module through the wire harness. The heated seat elements cannot be repaired. If found to be damaged or faulty, a new heating element assembly must be installed. Second Row DESCRIPTION Vehicles equipped with the optional heated second row seat system have four, carbon fiber heated second row seat elements. One element for each second row seat back and seat cushion. The elements are integral to the second row seat cushion and seat back foam and cannot be removed, once installed at the factory. Each of the heated second row seat elements consists of multiple heating circuits operating in parallel throughout the carbon fiber element. The heated second row seat elements are permanently secured to the seat foam assembly. If a malfunction occurs in one or more of the individual carbon fiber circuits, the others will continue to provide heat. The heated second row seat elements cannot be repaired. If found to be damaged or inoperative, a new heating element assembly must be installed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Description and Operation > Heated Seats - Description > Page 9317 Seat Heater: Description and Operation Heater Pad - Operation Front Seats OPERATION One end of the heated seat element resistor wire is connected to ground at all times through a splice under the seat. Battery current is directed to the other end of the heated seat element resistor wire by the energized N-channel Field Effect Transistor located within the heated seat module. The heated seat module will energize the N-FET when the heated seat switch is depressed in the Low or High position. As electrical current passes through the heating element grid, the resistance of the wire used in the element disperses some of that electrical current in the form of heat. The heat produced by the heated seat element grid then radiates through the underside of the seat cushion and seat back trim covers, warming the seat cover and its occupant. Second Row OPERATION One end of the heated second row seat element is connected to ground at all times through a splice and connector under the rear center floor console. Battery current is directed to the other end of the heated second row seat element by the heated seat switch/module. The heated seat switch/module will energize the heated second row seat element when the heated seat switch/module button is depressed in the Low or High position. As electrical current passes through the heated second row seat element, the resistance of the wire used in the element disperses some of the electrical current in the form of heat. The heat produced by the heated second row seat element then radiates through the underside of the seat cushion and seat back trim covers, warming the seat cover and its occupant. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Front Heated Seat System Seat Heater: Testing and Inspection Front Heated Seat System HEATED SEAT SYSTEM In order to obtain conclusive testing of the heated seat system, the Controller Area Network (CAN) data bus system must be checked. The most reliable, efficient, and accurate means to diagnose the heated seat system requires the use of a Scan Tool and the Service and Body Diagnostic Information. The Scan Tool can provide vital information to the technician trying to find a problem with the heated seat system. Diagnostic logic is built into the heated seat module and the instrument cluster (CCN) to help the person trying to locate the problem by the most efficient means possible. Anytime a problem is suspected, a Scan Tool should be obtained and used to retrieve any stored fault codes in the heated seat module and/or instrument cluster. If diagnostic fault codes are present in the module, record them on a piece of paper immediately before proceeding any further. Then, use these fault codes to identify the problem by verifying the fault code. Example, If the module records "DRIVER SEAT HEAT OUTPUT OPEN" fault code, locate the diagnostic procedure for this code in the appropriate Body Diagnostic information and follow the steps until the specific problem is located and resolved. Once the problem is thought to be corrected, erase the stored fault code using the Scan Tool and verify correct system operation. If the heated seat system is functioning correctly, verify that there are no other stored codes in the module and return the vehicle to service. If the fault code could not be verified, such as not finding anything wrong when following the diagnostic steps in the Body Diagnostic information. This is a good indication that a INTERMITTENT problem may be present. You must than attempt to find the intermittent problem, such as moving the heating element within the seat while testing continuity or wiggling the wire harness/electrical connectors under the seat while testing continuity. Always, eliminate all other potential problems before attempting to replace module. PRELIMINARY TEST Before testing the individual components in the heated seat system, check the following: - Using Scan Tool, check the heated seat module for any stored fault codes. Record these codes on paper for reference and resolve using the appropriate Body Diagnostic information. - Check the vehicles battery open-circuit voltage and charging system performance. If the vehicles electrical system is defective or weak it may not be suppling sufficient energy to operate the heated seat system. - If the heated seat switch backlighting does not light with the ignition switch in the On position, check the fused ignition switch fuse in the integrated power module. If OK, See: Seat Heater Switch/Testing and Inspection. If not OK, repair the shorted circuit or component as required and replace the faulty fuse or repair the open ground circuit as required. - If the heated seat switch HI/LO LED indicators do not light with the ignition switch in the On position and the heated seat switch in the Low or High position, check the fused ignition switch fuse in the integrated power module. If OK, See: Seat Heater Switch/Testing and Inspection. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Front Heated Seat System > Page 9320 Seat Heater: Testing and Inspection Front Seats HEATED SEAT ELEMENT The wire harness connectors (2AND3) for the heating elements are located under the seat (1). NOTE: When checking heated seat elements for continuity, be certain to move the heating element being checked. Moving the element, such as sitting in the seat will eliminate the possibility of an intermittent open in the element which would only be evident if the element was in a certain position. Failure to check the element in various positions could result in an incomplete test. 1. Locate and disconnect the seat electrical connector. 2. Check for continuity between the circuit leading in and out of the appropriate heated seat element. There should be continuity (less than 6 ohms). If OK, See: Seat Heater Control Module/Testing and Inspection. If not OK, replace the heated seat element. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Front Heated Seat System > Page 9321 Seat Heater: Testing and Inspection Second Row Heated Seat System HEATED SECOND ROW SEAT SYSTEM There are two methods of diagnosing the heated second row seat system. The "HEATED SEAT SYSTEM SELF-DIAGNOSIS" is to be performed when the system is inoperative and one or more of the heated seat switch/module Light Emitting Diode (LED) indicator lamps are flashing. The "HEATED SEAT SYSTEM BASE DIAGNOSIS" is to be performed when the system is inoperative and no LEDs are flashing or lighting when the switch/module buttons are pressed. HEATED SEAT SYSTEM SELF-DIAGNOSIS NOTE: Before testing the individual components in the heated second row seat system, check the vehicles battery open-circuit voltage and charging system performance. If the vehicles electrical system is defective or weak it may not be suppling sufficient energy to operate the heated second row seat system. The heated second row seat system is capable of performing some self-diagnostics. The following table depicts the various monitored failures which will be reported to the vehicle operator or technician by flashing the individual heated seat switch/module Light Emitting Diode (LED) indicator lamps. Heated Second Row Seat System Self-Diagnosis Table for failure identification. The left heated seat switch/module indicator lamps will flash if a failure occurs in the left heated second row seat, and the right heated seat switch/module indicator lamps will flash for a right heated second row seat failure. If a monitored heated second row seat system failure occurs, the switch/module indicator lamps will flash at a pulse rate of about one-half second on, followed by about one-half second off for a duration of about one minute after the switch/module for the inoperative heated second row seat is depressed in either the Low or High direction. This process will repeat every time the inoperative heated seat switch/module is actuated until the problem has been corrected. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. Heated Second Row Seat System Self-Diagnosis Table Diagnostic logic is built into the heated seat switch/module to help locate the problem by the most efficient means possible. Anytime a problem is suspected, locate the diagnosis and testing procedure for the component in question and follow the steps until the specific problem is located and resolved. Once the problem is thought to be corrected, verify correct system operation. If the heated second row seat system is functioning correctly return the vehicle to service. If a problem could not be verified such as not finding anything wrong when following the diagnostic procedure, this is a good indication that an INTERMITTENT problem may be present. You must then attempt to find the intermittent problem by moving the heating element within the seat while testing continuity or wiggling the wire harness's/electrical connectors under the seat while testing continuity. Always, eliminate all other potential problems before attempting to replace the heated seat switch/module. HEATED SEAT SYSTEM BASE DIAGNOSIS NOTE: Before testing the individual components in the heated second row seat system, check the vehicles battery open-circuit voltage and charging system performance. If the vehicles electrical system is defective or weak it may not be suppling sufficient energy to operate the heated second row seat system. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. PRELIMINARY TEST - If a single LED indicator lamp for one heated seat switch/module does not operate and the heated second row seat elements heat, replace the switch with the inoperative indicator lamp . See: Seat Heater Switch/Service and Repair/Heated Seat Switch - Removal - If both LED indicator lamps for a heated seat switch/module operate, but the heated second row seat elements do not heat, See: to check the suspect heated second row seat elements. If the elements test OK, proceed to 1. - If both second row seats fail to heat and the indicator lamps on the heated seat switch/modules for both seats fail to operate, test the heated second Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Front Heated Seat System > Page 9322 row seat fuses in the Integrated Power Module (IPM). If the heated second row seat fuses check OK, go to 1. LEFT SECOND ROW HEATED SEAT SWITCH/MODULE 1. Remove the heated seat switch/modules from the second row center floor console, . See: Seat Heater Switch/Service and Repair/Heated Seat Switch - Removal 2. Connect the battery negative cable. 3. Turn the ignition to the "RUN" position. 4. Check for battery voltage on terminals 4 and 6 of the switch/module connector of the inoperative seat. Battery voltage should be present on both terminals. If OK go to 5. If NOT OK repair the open or shorted fused B(+) circuit as required. 5. Check for continuity between ground terminal 1 of the switch/module connector of the inoperative seat and a good ground. If OK go to 6. If NOT OK, repair the open or shorted ground circuit as required. 6. Check for continuity between the heated second row seat element supply circuit terminal 3 of the switch/module connector of the inoperative seat and the heated second row seat element connector of the inoperative seat. If OK go to 7. If NOT OK, repair the open or shorted supply circuit as required. 7. Perform the heated second row seat element diagnosis for the inoperative seat. See: to check the suspect heated second row seat elements. If the elements test OK, replace the inoperative heated seat switch/module, See: Seat Heater Switch/Service and Repair/Heated Seat Switch - Removal for the appropriate procedure. If NOT OK, replace the inoperative heated second row seat element, See: Service and Repair/Heater Pad - Removal for the appropriate procedure. RIGHT SECOND ROW HEATED SEAT SWITCH/MODULE 1. Remove the heated seat switch/modules from the second row center floor console, See: Seat Heater Switch/Service and Repair/Heated Seat Switch - Removal. 2. Connect the battery negative cable. 3. Turn the ignition to the "RUN" position. 4. Check for battery voltage on terminals 4 and 6 of the switch/module connector of the inoperative seat. Battery voltage should be present on both terminals. If OK go to 5. If NOT OK repair the open or shorted fused B(+) circuit as required. 5. Check for continuity between ground terminal 1 of the switch/module connector of the inoperative seat and a good ground. If OK go to 6. If NOT Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Front Heated Seat System > Page 9323 OK, repair the open or shorted ground circuit as required. 6. Check for continuity between the heated second row seat element supply circuit terminal 3 of the switch/module connector of the inoperative seat and the heated second row seat element connector of the inoperative seat. If OK go to 7. If NOT OK, repair the open or shorted supply circuit as required. 7. Perform the heated second row seat element diagnosis for the inoperative seat. See: to check the suspect heated second row seat elements. If the elements test OK, replace the inoperative heated seat switch/module, See: Seat Heater Switch/Service and Repair/Heated Seat Switch - Removal for the appropriate procedure. If NOT OK, replace the inoperative heated second row seat element, See: Service and Repair/Heater Pad - Removal for the appropriate procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection > Front Heated Seat System > Page 9324 Seat Heater: Testing and Inspection Second Row HEATED REAR SEAT ELEMENT Refer to the appropriate wiring information for complete circuit schematic or connector pin-out information. The wire harness connectors (2) for the second row cushion heating elements are located under the rear center floor console on the console bracket (1). The harness connectors can be accessed by removing the rear center floor console. The wire harness connectors (3) for the second row seat back (1) heating elements are located on the inner second row seat cushion (2) to seat back bracket. The harness connector can be accessed by removing the bracket trim cover. NOTE: When checking heated second row seat elements for continuity, be certain to move the heating element being checked. Moving the element, such as sitting in the seat will eliminate the possibility of an intermittent open in the element which would only be evident if the element was in a certain position. Failure to check the element in various positions could result in an incomplete test. 1. Locate and disconnect the seat electrical connector. 2. Check the resistance between the circuit leading in and out of the suspect heated seat element. The resistance should be between 3.8 - 4.8 ohms for a seat cushion element and 4.3 - 5.4 ohms for a seat back element. If OK, See: for further heated second row seat system diagnosis. If not OK, replace the inoperative heated second row seat element. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Heater Pad - Removal Seat Heater: Service and Repair Heater Pad - Removal Front Seats REMOVAL NOTE: The original heater elements can be removed from the foam cushion by carefully peeling the element off along the adhesive lines. 1. Disconnect and isolate the negative battery cable. 2. Remove the appropriate seat cushion or seat back trim coverSee: Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 3. Disconnect the inoperative heated seat cushion or seat back element electrical connectors (2). 4. Remove the inoperative heater element from the cushion or seat back, being careful not to remove excessive foam in the process. Second Row REMOVAL NOTE: The factory installed heater elements can be removed from the foam cushion by carefully peeling the element off along the adhesive lines. SEAT CUSHION ELEMENT 1. Disconnect and isolate the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Heater Pad - Removal > Page 9327 2. Remove the appropriate seat cushion cover, See: Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 3. Remove the rear center floor console, See: Interior Moulding / Trim/Console/Service and Repair/Rear Center Console - Removal. 4. Disconnect the inoperative heated second row seat cushion element electrical connector (2) and remove the harness routing clip from the console bracket (1). 5. Remove the heater element by peeling it away from the foam cushion, being careful not to remove excessive foam in the process. SEAT BACK ELEMENT 1. Disconnect and isolate the battery negative cable. 2. Remove the appropriate seat back trim cover (1), See: Seat Cover/Service and Repair/Seat Cushion Cover - Removal. 3. Remove the inner second row seat cushion (2) to seat back (1) bracket trim cover. 4. Disconnect the inoperative heated second row seat back element electrical connector (3) and remove the harness routing clip. 5. Remove the heater element by peeling it away from the foam cushion, being careful not to remove excessive foam in the process. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Heater Pad - Removal > Page 9328 Seat Heater: Service and Repair Heater Pad - Installation Front Seats INSTALLATION CAUTION: During the installation of the replacement heating element, be careful not to fold or crease the element assembly. Folds or creases will cause premature failure. 1. Install the new heater element by peeling off the adhesive backing and placing it directly on the foam cushion where the original heating element was. 2. Connect the new heater element electrical connectors (1 and 2). 3. Connect the battery negative cable. 4. Verify heated seat system operation. 5. Install the appropriate seat cushion or seat back trim cover. Make certain the seat wire harness is correctly routed through the seat and seat back. The excess wire between the cushion and back elements should be securely tucked between the rear of the cushion foam and the rear carpet flap of the trim cover. Second Row INSTALLATION SEAT CUSHION ELEMENT Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Heater Pad - Removal > Page 9329 CAUTION: During the installation of the replacement heating element, be careful not to fold or crease the element assembly. Folds or creases will cause premature failure. 1. Install the new heater element by peeling off the adhesive backing and placing it directly where the factory installed heater element was. 2. Connect the heated second row seat cushion element electrical connector (2) and install the harness routing clip to the rear center floor console bracket (1). 3. Install the rear center floor consoleSee: Interior Moulding / Trim/Console/Service and Repair/Rear Center Console - Installation. 4. Connect the battery negative cable. 5. Verify heated rear seat system operation. 6. Install the appropriate seat cushion cover, See: Seat Cover/Service and Repair/Seat Cushion Cover - Installation. NOTE: Make certain the seat wire harness is correctly routed through the seat and seat back. The excess wire between the cushion and back elements should be securely tucked between the rear of the cushion foam and the rear carpet flap of the trim cover. SEAT BACK ELEMENT Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Heater Pad - Removal > Page 9330 CAUTION: During the installation of the replacement heating element, be careful not to fold or crease the element assembly. Folds or creases will cause premature failure. NOTE: Second row heated seat cushion shown, second row heated seat back similar. 1. Install the new heater element by peeling off the adhesive backing and placing it directly where the factory installed heater element was. 2. Connect the heated second row seat back element electrical connector (3) and install the harness routing clip. 3. Connect the battery negative cable. 4. Verify heated rear seat system operation. 5. Install the appropriate seat back trim cover (1), See: Seat Cover/Service and Repair/Seat Back Cover - Installation. NOTE: Make certain the seat wire harness is correctly routed through the seat and seat back. The excess wire between the cushion and back elements should be securely tucked between the rear of the cushion foam and the rear carpet flap of the trim cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Locations > Page 9334 Seat Heater Control Module: Diagrams Connector - (BODY) 6 WAY MODULE-HEATED SEAT - (BODY) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description Seat Heater Control Module: Description and Operation Heated Seat Module - Description DESCRIPTION The heated seat module (2) is located behind the right rear D-pillar trim (1). The heated seat module has a single electrical connector (3). The heated seat module is an microprocessor designed to use CAN bus messages from the cluster Cabin Compartment Node (CCN) to operate the heated seat elements in both front seats. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Heated Seat Module - Description > Page 9337 Seat Heater Control Module: Description and Operation Heated Seat Module - Operation OPERATION The heated seat module operates on fused battery current received from the ignition switch. The module is grounded at all times through a ground lug on the right rear D-pillar. Inputs to the module include CAN bus messages and standard hardwired 12volt power and ground. In response to those inputs the heated seat module controls the battery current to the heated seat elements. When a heated seat switch CAN bus signal is received by the heated seat module, the module energizes the selected heated seat element. The Low heat set point is about 38°C (100.4°F), and the High heat set point is about 42°C (107.6°F). If the heated seat module detects a heated seat element OPEN or SHORT circuit, it will record and store an diagnostic trouble code (DTC). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Description and Operation > Page 9338 Seat Heater Control Module: Testing and Inspection HEATED SEAT MODULE 1. Test the appropriate heated seat element See: Seat Heater/Testing and Inspection. 2. Test the appropriate heated seat switch. 3. Using a voltmeter, backprobe the heated seat module connector, do not disconnect. Check for voltage at the appropriate pin cavities. 12v should be present. If OK go to 4 , if Not, repair the open or shorted voltage supply circuit as required. 4. Using a ohmmeter, backprobe the appropriate heated seat module connector, do not disconnect. Check for proper continuity to ground on the ground pin cavities. Continuity should be present. If OK test the Cabin compartment Node (CCN) cluster using a scan tool for proper heated seat system function. If Not OK, Repair the open or shorted ground circuit as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal Seat Heater Control Module: Service and Repair Heated Seat Module - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Open the liftgate and remove the upper D-pillar trim from the vehicle. See: Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Removal. 3. Remove the lower D-pillar trim from the vehicle. See: Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Removal . 4. Disconnect the wire harness connector from the back of the heated seat module (2). 5. Unsnap the heated seat module (2) from the D-pillar (1). 6. Remove the heated seat module (2) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Heated Seat Module - Removal > Page 9341 Seat Heater Control Module: Service and Repair Heated Seat Module - Installation INSTALLATION 1. Install the heated seat module on the D-pillar (1). 2. Connect the wire harness connector (3) to the heated seat module (2). 3. Reconnect the negative battery cable. 4. Check for proper heated seat system operation. 5. Install the upper and lower D-pillar trim to the vehicle. See: Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Installation. 6. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Driver Heated Seat Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Driver Heated Seat Switch > Page 9346 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Driver Heated Seat Switch (Instrument Panel) 6 Way Seat Heater Switch: Diagrams Driver Heated Seat Switch (Instrument Panel) 6 Way Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-HEATED SEAT-DRIVER - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Driver Heated Seat Switch (Instrument Panel) 6 Way > Page 9349 Seat Heater Switch: Diagrams Left Rear Heated Seat Switch (Rear Seat) 6 Way Connector - (REAR SEAT) 6 WAY SWITCH-HEATED SEAT-LEFT REAR - (REAR SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Driver Heated Seat Switch (Instrument Panel) 6 Way > Page 9350 Seat Heater Switch: Diagrams Passenger Heated Seat Switch (Instrument Panel) 6 Way Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-HEATED SEAT-PASSENGER - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Driver Heated Seat Switch (Instrument Panel) 6 Way > Page 9351 Seat Heater Switch: Diagrams Right Rear Heated Seat Switch (Rear Seat) 6 Way Connector - (REAR SEAT) 6 WAY SWITCH-HEATED SEAT-RIGHT REAR - (REAR SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description Seat Heater Switch: Description and Operation Heated Seat Switch - Description Front DESCRIPTION The heated seat switches are both mounted in the instrument panel. The two switches are snapped into mounting holes in the instrument panel center bezel (1). The two heated seat switches (2) and (3) are identical in appearance and construction, except for the location of a keyway in the connector receptacle on the back of each switch. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles so that the two heated seat switches can only be connected to the proper heated seat. Each momentary, bidirectional rocker-type heated seat switch provides a resistor-multiplexed signal to the Cab Compartment Node (CCN). Each switch has a center neutral position and momentary Low and High positions so that the driver and the front seat passenger can select a preferred seat heating level. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Each switch also has one indicator lamp for back lighting of the switch when the ignition switch is in the Run position. The five LED indicator lamps in each heated seat switch cannot be repaired. If the LED lamps are faulty or damaged, or the switch is faulty or damaged the individual heated seat switch assembly must be replaced. Second Row DESCRIPTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description > Page 9354 Momentary contact push button switch/modules (2) mounted in the front face of the second row center floor console (3) operate the heated second row seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated second row seat system. If any of the heated second row seat elements are inoperative or damaged one or more of the LED lamps in the switch/module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are inoperative or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. See: Service and Repair/Heated Seat Switch Removal for the switch/module replacement procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description > Page 9355 Seat Heater Switch: Description and Operation Heated Seat Switch - Operation Front OPERATION The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistor multiplexed signal to the Cabin Compartment Node (CCN). The CCN is responsible for supplying the CAN bus message to the heated seat module, signaling the module to power the heated seat element of the selected seat and maintain the temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the CCN will go through the process again to change the temperature setting. If a heated seat switch is depressed a second time to the same position as the currently selected state, the CCN and heated seat module interprets the second input as a request to turn the seat heater OFF. The CCN will then signal the heated seat module to turn the heated seat elements for that seat off. The backlighting LED's in each of the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The ground side of the indicator lamp is divided by a separate lamp driver circuit in the CCN. Second Row OPERATION A Heated Seat Switch/Module is used to control the heated second row seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after thirty minutes of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue for another thirty minutes and the system will then be automatically turned off. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and Operation > Page 9356 Seat Heater Switch: Testing and Inspection HEATED SEAT SWITCH Refer to the Wiring section for complete heated seat system wiring diagrams. WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the heated seat elements do heat, disconnect the inoperative switch and check for continuity between the ground pin at the heated seat switch connector and ground. If there is no continuity, repair an open wire between ground and the heated seat switch connector. If there is continuity, replace the inoperative heated seat switch. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned Off, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Also refer to the Body Diagnostic Information for additional diagnosis and testing procedures. 2. Check the fused ignition switch output (run) fuse in the Power Distribution Center (PDC). If OK, go to 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run) fuse in the PDC. If OK, go to 4. If not OK, repair the open fused ignition switch output (run) circuit to the ignition switch as required. 4. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector from the connector receptacle on the back of the heated seat switch to be tested. Reconnect the battery negative cable. Turn the ignition switch to the Run position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the heated seat switch. If OK, go to 5. If not OK, repair the open fused ignition switch output (run) circuit to the PDC fuse as required. 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart below. If OK, See: Seat Heater Control Module/Testing and Inspection. Also refer to the Body Diagnostic Information for additional diagnosis and testing procedures. If not OK, replace the faulty heated seat switch. HEATED SEAT SWITCH CONTINUITY CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal Seat Heater Switch: Service and Repair Heated Seat Switch - Removal Front REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the center bezel (1) from the instrument panel See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the heated seat switch bezel and both switches from the center bezel as a unit. 4. From the back of the heated seat switch bezel (2), gently pry the switch free and push the heated seat switch out through the rear of the bezel. Second Row REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 9359 1. Disconnect and isolate the battery negative cable. 2. Using an appropriate flat bladed tool, remove the heated seat switch/modules (2) from the rear center floor console (3) by gently prying up from the edge of the switch/module bezel (1). Take care not to scratch or damage the console or bezel in any way. 3. Disconnect the switch/module electrical connectors (2) and (4). 4. Using an appropriate flat bladed tool, remove the heated seat switch/module (3) from the bezel (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 9360 Seat Heater Switch: Service and Repair Heated Seat Switch - Installation Front INSTALLATION NOTE: When installing the heated seat switches, be certain they are installed in the proper mounting holes of the heated seat switch bezel (2). The heated seat switches are identified by a keyway in the connector receptacle on the back of each switch. 1. From the back of the heated seat switch bezel, gently push the heated seat switch in through the rear of the bezel. 2. Install the center bezel on the instrument panel See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Cluster Bezel - Installation. 3. Connect the battery negative cable. 4. Verify heated seat system operation. Second Row INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 9361 1. Align the tabs (1) of the switch/module (2) to the bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors (2) and (4). 3. Gently push the heated seat switch/module bezel (1) into the mounting hole in the center console (3) until it is securely in place. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Hood Ajar Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Hood Ajar Switch > Page 9368 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Locations > Page 9369 Hood Sensor/Switch (For Alarm): Diagrams Connector (HEV) - 2 WAY SWITCH-HOOD AJAR 2 (HEV) - 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Description DESCRIPTION The hood ajar switch is a normally closed, single pole, spring-loaded plunger actuated switch. This switch has two unique versions that are used in three different applications. One switch is used only on vehicles equipped with the Vehicle Theft Alarm (VTA) system for sale in certain export markets where protection of the underhood area is required equipment. The second switch is used only on domestic market vehicles equipped with either an optional remote starter system or the optional Hybrid Electric Vehicle (HEV) system. The molded plastic switch body (5) has an integral molded connector receptacle (1) on the lower end containing two terminal pins. The switch is connected to the vehicle electrical system through a dedicated take out of the headlamp and dash wire harness. Two integral latches (2) lock the switch into a keyed mounting hole. For the vehicle theft and remote start applications, the switch is secured within the stamped metal inner left fender mounting flange within the engine compartment. For the HEV applications, the switch is secured within the stamped metal inner right fender mounting flange within the engine compartment. A molded plastic striker secured to the underside of the hood panel inner reinforcement actuates the switch plunger as the hood panel is closed. The switch plunger (3) extends through a mounting collar (4) and a sleeve-like retainer ring on the upper end of the switch body. The retainer ring has a one time, self-adjustment feature that is activated after the switch is installed by closing the hood. The retainer ring is also color-coded to aid in identifying the switch application. A dark brown retainer ring identifies the underhood security switch application, while a white retainer ring identifies the remote starter system or HEV system application. An installed hood ajar switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or requires readjustment, it must be replaced with a new unit. The hood ajar switch striker is not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced with a new unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Description and Operation > Vehicle Theft Security Hood Ajar Switch - Description > Page 9372 Hood Sensor/Switch (For Alarm): Description and Operation Vehicle Theft Security Hood Ajar Switch - Operation OPERATION The hood ajar switches are interchangeable physically, but not functionally. In each case, the hood ajar switch is a normally closed switch that is held open as the spring-loaded switch plunger is depressed by the striker on the inner hood panel reinforcement when the hood panel is closed and latched. When the hood is opened, the spring-loaded switch plunger extends from the switch body and the switch contacts are closed. In the underhood security application (export market vehicles only - dark brown retainer ring), the switch is connected in series between ground and the hood ajar switch sense input of the Front Control Module (FCM). The FCM uses an internal resistor pull up to monitor the state of the hood ajar switch contacts. In the remote starter system application (domestic market vehicles only - white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between an output of the FCM and the hood ajar switch sense input of the FCM. The FCM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. When the hood switch is closed (hood is open), the remote start feature is disabled. In the Hybrid Electric Vehicle (HEV) system application (white retainer ring) the switch has a 1 kilo ohm diagnostic resistor connected in parallel to the switch contacts between the two switch terminals. The switch is connected in series between ground and the hood ajar switch sense input of the Powertrain Control Module (PCM). The PCM continually monitors this circuit and will store a Diagnostic Trouble Code (DTC) for any fault that it detects. When the hood switch is closed (hood is open), the gasoline engine auto-start feature is disabled. The components of the switch self-adjustment feature include an integral stop on the shaft of the plunger and a ribbed, ratcheting sleeve-like retainer ring at the top of the switch body from which the plunger extends. With the switch mounting collar secured in its mounting hole, the plunger is depressed by the striker on the hood inner reinforcement as the hood is closed. As the plunger is depressed, the plunger stop contacts the top of the retainer ring and it is driven downward, ratcheting through the switch mounting collar until the hood is fully closed and latched. The ribs on the retainer ring are engaged within the mounting collar to maintain this adjusted position. The hood ajar switch as well as the hard wired circuits between the switch and the FCM or PCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the electronic controls or communication between modules and other devices related to hood ajar switch operation that provide some features of the export market vehicle theft, domestic market remote starter or the HEV systems. The most reliable, efficient, and accurate means to diagnose the electronic controls and communication related to hood ajar switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Removal Striker STRIKER NOTE: Vehicles equipped with two hood ajar switches are also equipped with two strikers. NOTE: The hood ajar switch strikers are not intended for reuse. If the striker is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Unlatch and open the hood. 2. Using hand pressure, slide the hood ajar switch striker (2) toward the large end of the keyed mounting hole (3) in the inner hood panel reinforcement (1) far enough to disengage it. 3. Remove the striker from the inner hood panel reinforcement and discard. Switch SWITCH NOTE: Some vehicles are equipped with two hood ajar switches. 1. Unlatch and open the hood. 2. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 3. From the top of the left or right front fender inner shield, squeeze the two hood ajar switch latch tabs (1) together and pull the switch upward out of Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal > Page 9375 the mounting hole (2). 4. Pull the hood ajar switch up through the hole far enough to access and disconnect the wire harness connector (3) from the switch connector receptacle. 5. Remove the hood ajar switch from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal > Page 9376 Hood Sensor/Switch (For Alarm): Service and Repair Vehicle Theft Security Hood Ajar Switch Installation Striker STRIKER NOTE: Vehicles equipped with two hood ajar switches are also equipped with two strikers. NOTE: The hood ajar switch striker caps are not intended for reuse. If the striker cap is removed from the hood inner reinforcement for any reason, it must be replaced. 1. Position the new hood ajar switch striker (2) into the large end of the keyed mounting hole (3) in the inner hood panel reinforcement (1) over the hood ajar switch. 2. Using hand pressure, slide the striker upward into the small end of the mounting hole in the inner hood panel reinforcement until it is fully engaged. 3. Close and latch the hood. Switch SWITCH NOTE: Some vehicles are equipped with two hood ajar switches. 1. Position the hood ajar switch (1) near the mounting hole (2) in the left front fender inner shield. 2. Reconnect the wire harness connector (3) to the switch connector receptacle. 3. Insert the switch into the mounting hole until the integral switch latch tabs lock it into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair > Vehicle Theft Security Hood Ajar Switch Removal > Page 9377 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. 5. Close and latch the hood. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Sensor > Component Information > Locations > Page 9381 Pedal Positioning Sensor: Diagrams Connector - (INSTRUMENT PANEL) 3 WAY SENSOR-ADJUSTABLE PEDALS - (INSTRUMENT PANEL) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Locations > Page 9385 Pedal Positioning Switch: Diagrams Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-ADJUSTABLE PEDALS - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Service and Repair > Removal Pedal Positioning Switch: Service and Repair Removal REMOVAL 1. Remove the lower drivers side bezel. 2. Disconnect the electrical connector (2) from the adjustable pedal switch (1). 3. Remove the switch from the lower drivers side bezel by squeezing the retaining clips together and pushing the switch outwards Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Pedal Positioning Switch > Component Information > Service and Repair > Removal > Page 9388 Pedal Positioning Switch: Service and Repair Installation INSTALLATION 1. Install the switch (1) to the lower drivers side bezel by pushing the switch inwards seating the retaining clips to the lower drivers side bezel. 2. Reconnect the electrical connector (2) to the adjustable pedal switch (1). 3. Install the lower drivers side bezel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Driver Window/Door Lock Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Driver Window/Door Lock Switch > Page 9393 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Left Front Door) 8 Way Power Door Lock Switch: Diagrams Driver Window/Door Lock Switch C1 (Left Front Door) 8 Way Connector C1 - (LEFT FRONT DOOR) 8 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (LEFT FRONT DOOR) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Left Front Door) 8 Way > Page 9396 Power Door Lock Switch: Diagrams Driver Window/Door Lock Switch C2 (Left Front Door) 6 Way Connector C2 - (LEFT FRONT DOOR) 6 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (LEFT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Driver Window/Door Lock Switch C1 (Left Front Door) 8 Way > Page 9397 Power Door Lock Switch: Diagrams Passenger Window/Door Lock Switch (Right Front Door) 6 Way Connector - (RIGHT FRONT DOOR) 6 WAY SWITCH-WINDOW/DOOR LOCK-PASSENGER - (RIGHT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Power Lock Switch - Description Power Door Lock Switch: Description and Operation Power Lock Switch - Description DESCRIPTION A window/lock switch located in each front door trim panel. The driver's side window/lock switch includes the following: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Window Lockout Switch - A two-way, latching, push-button switch allows the vehicle operator to lock out the power window switches on each passenger door so that the passenger door power windows may be operated only from the master switches. - Power Window Switches - A two-way, momentary power window switch for the driver side front door also has a second detent in the Down direction and internal circuitry to provide an Auto-Down feature for the driver side front door power window. In addition to the power window switch for its own door, the window/lock switch houses individual master switches for each passenger door power window. The passenger side window/lock switch includes the following: - Power Lock Switch - A two-way, momentary, resistor multiplexed switch to control the power lock system. - Power Window Switch - A two-way, momentary power window switch for the passenger side front door. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Power Lock Switch - Description > Page 9400 Power Door Lock Switch: Description and Operation Power Lock Switch - Operation OPERATION The driver side window/lock switch combines a power lock switch, a driver power window switch with an Auto-down feature, master switches for each passenger door power window, a power window lockout switch, a power mirror selector switch, and four power mirror adjustment switches in a single assembly. The switches in the window/lock switch can be diagnosed using conventional diagnostic tools and methods. Power Lock Switch The power lock switch circuitry is connected in series between ground and the driver door switch mux input of the instrument cluster (without memory). If equipped with the memory system, the circuitry is connected to the memory mirror module. Each power lock switch position (Lock, Unlock, and Neutral) provides a different resistance value to the instrument cluster or memory mirror input, which allows the instrument cluster or memory module to sense the switch position. Based upon the power lock switch input, the instrument cluster or memory module controls the battery and ground feed outputs to the individual power lock motors to lock or unlock the door latches. The Light-Emitting Diode (LED) in the power lock switch is connected to battery current through the power window circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the switch will be illuminated whenever the ignition switch is in the On or Accessory positions. Power Window Switches The power window switch circuitry is connected to battery current through a circuit breaker in the Integrated Power Module (IPM) on a fused ignition switch output (run-acc) circuit so that the power windows will operate whenever the ignition switch is in the On or Accessory positions. Each two-way, momentary master passenger power window switch in the window/lock switch provides battery current and ground to the individual power window switches on each passenger door so that the power window switch controls the battery current and ground feeds to its respective power window motor. The switch for the driver side front door power window includes an auto-down feature. When this switch is depressed to a second momentary detent position and released, the driver door power window is automatically operated through an internal circuit and relay to its fully lowered position. The Auto-down event is cancelled if the switch paddle is depressed a second time in either the Up or Down direction. When the two position window lockout switch in the window/lock switch is depressed and latched in the lockout position, the battery current feed to each of the individual passenger power window switches is interrupted so that the passenger door power windows can only be operated from the switches in the window/lock switch. The window lockout switch also controls the battery current feed for the LED in each passenger power window switch so that the switch will not be illuminated when it is locked out. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Description and Operation > Page 9401 Power Door Lock Switch: Testing and Inspection WINDOW/DOOR LOCK SWITCH The Light-Emitting Diode (LED) illumination lamps for all of the window/lock switch power window and power lock switches receive battery current through the circuit breaker in the Integrated Power Module (IPM). If only one LED in the door module is inoperative, replace the faulty door module. If the driver side front door power window operates in a normal manner, but the Auto-Down feature is inoperative, replace the faulty window/lock switch. Refer to the appropriate wiring information. 1. Disconnect and isolate the negative battery cable. Remove the window/lock switch from the door trim panel. Disconnect the door wire electrical connectors from the switch. 2. Test the switch continuity. See the Switch Tests chart to determine if the continuity is correct for the suspect switches in each switch position. If not OK, replace the faulty window/lock switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal Power Door Lock Switch: Service and Repair Power Lock Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, start at the rear of the switch and pry up to remove from door trim panel. 3. Disconnect electrical harness connectors from switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Service and Repair > Power Lock Switch - Removal > Page 9404 Power Door Lock Switch: Service and Repair Power Lock Switch - Installation INSTALLATION 1. Connect electrical harness connectors to switch. 2. Insert front end of switch into door trim panel opening. Press into place. 3. Connect battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 9408 Power Mirror Switch: Diagrams Connector - (LEFT FRONT DOOR) 10 WAY SWITCH-MIRROR - (LEFT FRONT DOOR) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Power Mirror Switch - Description Power Mirror Switch: Description and Operation Power Mirror Switch - Description DESCRIPTION A power mirror switch is located on the driver's door trim panel, attached to the window/lock switch. The power mirror switch includes the following: - Power Mirror Selector Switch - A three-position rotary joystick switch selects the right or left power mirror for adjustment, or turns the power mirror system Off in the center position. - Power Mirror Adjustment Switch - A momentary joystick directional switch allows the driver to adjust the selected power mirror in the Up, Down, Right or Left directions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Power Mirror Switch - Description > Page 9411 Power Mirror Switch: Description and Operation Power Mirror Switch - Operation OPERATION The power mirror switch circuitry is connected to battery current through a fuse in the IPM on a fused B(+) circuit so that the power mirrors remain operational regardless of the ignition switch position. A rotary joystick selector switch has three positions, one to select the right mirror, one to select the left mirror, and a center Off position. After the right or left mirror is selected, the joystick is moved to move the selected mirror Up, Down, Right or Left. In vehicles without Memory Mirrors the power mirror switch circuitry controls the battery current and ground feeds to each of the four (two in each mirror head) power mirror motors. In vehicles with Memory Mirrors the mirror switch connects to the driver power mirror module. The driver memory mirror module uses the mirror switch inputs to control the battery current and ground feeds to driver mirror motor and sends a CAN Bus message to the passenger mirror module. The passenger mirror module controls the battery current and ground feeds to passenger mirror motors based on the CAN bus message from the driver memory module. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Description and Operation > Page 9412 Power Mirror Switch: Testing and Inspection POWER MIRROR SWITCH 1. Disconnect and isolate the battery negative cable. Remove the power mirror switch. Disconnect the wire harness connector from the switch. 2. Test the switch continuity. See the Switch Tests chart to determine if the continuity is correct for the suspect switch in each switch position. If not OK, replace the inoperative switch as required. POWER MIRROR SWITCH TEST Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal Power Mirror Switch: Service and Repair Power Mirror Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the window/lock switch See: Power Door Lock Switch/Service and Repair/Power Lock Switch - Removal. 3. Remove the power mirror switch from the window/lock switch assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Power Mirror Switch - Removal > Page 9415 Power Mirror Switch: Service and Repair Power Mirror Switch - Installation INSTALLATION 1. Install power mirror switch to window/lock switch assembly. 2. Connect wire harness connectors to switches. 3. Install window/lock switch assembly See: Power Door Lock Switch/Service and Repair/Power Lock Switch - Installation. 4. Connect battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Driver Seat Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Driver Seat Switch > Page 9420 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver Seat Switch (Left Seat) 11 Way Power Seat Switch: Diagrams Driver Seat Switch (Left Seat) 11 Way Connector - (LEFT SEAT) 11 WAY SWITCH-SEAT-DRIVER - (LEFT SEAT) 11 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Driver Seat Switch (Left Seat) 11 Way > Page 9423 Power Seat Switch: Diagrams Passenger Seat Switch (Right Seat) 11 Way Connector - (RIGHT SEAT) 11 WAY SWITCH-SEAT-PASSENGER - (RIGHT SEAT) 11 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Power Seat Switch - Description Power Seat Switch: Description and Operation Power Seat Switch - Description DESCRIPTION The driver power seat can be adjusted in eight different ways using the power seat switch. The passenger power seat can be adjusted in four different ways. The power seat switch is located on the lower outboard side of the seat cushion on the seat cushion side shield on all models. The individual switches in the power seat switch assembly cannot be repaired. If one switch is damaged or inoperative, the entire power seat switch must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Power Seat Switch - Description > Page 9426 Power Seat Switch: Description and Operation Power Seat Switch - Operation OPERATION When a power seat switch is actuated, a battery feed and a ground path are applied through the switch contacts to the power seat adjuster or recliner adjuster motor. The selected adjuster motor operates to move the seat or recliner through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and ground path to the motor are reversed through the switch contacts. This causes the adjuster motor to run in the opposite direction. On vehicles equipped with memory system, a resistance signal is sent to the Memory Seat Module (MSM) via the Controller Area Network (CAN) bus circuit, when the driver memory seat switch control knob is actuated. The MSM is responsible for the 12v battery feed and ground path to the power seat adjuster motor. The adjuster motor operates to move the power seat adjuster mechanism through its drive unit in the selected direction until the switch is released, or until the travel limit of the adjuster is reached. No power seat switch should be held applied in any direction after the adjuster has reached its travel limit. The power seat adjuster motors each contain a self-resetting circuit breaker to protect them from overload. However, consecutive or frequent resetting of the circuit breaker may result in motor damage. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 9427 Power Seat Switch: Testing and Inspection POWER SEAT SWITCH DRIVER SEAT WITHOUT MEMORY 1. Disconnect and isolate the negative battery cable. 2. Remove the power seat switch from the power seat. See: Service and Repair/Power Seat Switch - Removal. 3. Use an ohmmeter to test the continuity of the power seat switch. Refer to DRIVER SEAT SWITCH WITHOUT MEMORY TEST table. If not OK, replace the inoperative power seat switch. If switch test OK, See: Seats/Testing and Inspection/Component Tests and General Diagnostics. PASSENGER SEAT 1. Disconnect and isolate the negative battery cable. 2. Remove the power seat switch from the power seat. See: Service and Repair/Power Seat Switch - Removal. 3. Use an ohmmeter to test the continuity of the power seat switch. Refer to PASSENGER SEAT SWITCH TEST table. If not OK, replace the inoperative power seat switch. If switch test OK, See: Seats/Testing and Inspection/Component Tests and General Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Description and Operation > Page 9428 DRIVER SEAT WITH MEMORY 1. Disconnect and isolate the negative battery cable. 2. Remove the power seat switch from the power seat. See: Service and Repair/Power Seat Switch - Removal. 3. Use an ohmmeter to test the continuity of the power seat switch. Refer to DRIVER SEAT SWITCH WITH MEMORY table. If not OK, replace the inoperative power seat switch. If switch test OK, See: Seats/Testing and Inspection/Component Tests and General Diagnostics. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch - Removal Power Seat Switch: Service and Repair Power Seat Switch - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the seat cushion side panel from the seat and disconnect the electrical harness connector. 3. Using a small flat bladed tool, gently release the four mounting tabs that secure the power seat switch and separate switch from trim panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Power Seat Switch - Removal > Page 9431 Power Seat Switch: Service and Repair Power Seat Switch - Installation INSTALLATION 1. Position the power seat switch on the seat cushion side panel. Gently apply pressure to the switch until the four mounting tabs that secure the switch snap into place. 2. Connect the power seat switch electrical connector. 3. Install the seat cushion side panel on the seat. 4. Connect the battery negative cable. 5. Verify normal operation of the power seat assembly. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations > Left Liftgate Pinch Sensor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Locations > Left Liftgate Pinch Sensor > Page 9436 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Diagrams > Left Liftgate Pinch Sensor (Power Liftgate) (Liftgate) 2 Way Power Trunk / Liftgate Hazard Sensor: Diagrams Left Liftgate Pinch Sensor (Power Liftgate) (Liftgate) 2 Way Connector (POWER LIFTGATE) - (LIFTGATE) 2 WAY SENSOR-LIFTGATE PINCH-LEFT (POWER LIFTGATE) - (LIFTGATE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Diagrams > Left Liftgate Pinch Sensor (Power Liftgate) (Liftgate) 2 Way > Page 9439 Power Trunk / Liftgate Hazard Sensor: Diagrams Right Liftgate Pinch/Temperature Sensor (Power Liftgate) (Liftgate) 2 Way Connector (POWER LIFTGATE) - (LIFTGATE) 2 WAY SENSOR-LIFTGATE PINCH/TEMP-RIGHT (POWER LIFTGATE) - (LIFTGATE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Description and Operation > Pinch Sensor - Description Power Trunk / Liftgate Hazard Sensor: Description and Operation Pinch Sensor - Description DESCRIPTION Pinch sensors (2) are located on each side of the liftgate (1). These sensors look like weather-strips, however they consist of pieces of electrically conductive rubber (tapeswitch), wires, resistor, double sided tape, and a plastic carrier. They are used to indicate an obstruction during a power liftgate close cycle. The right side pinch sensor contains a thermistor that is integral to the pinch sensor assembly. The thermistor is a temperature sensor used by the power liftgate control module to enable proper liftgate operation in extreme climate conditions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Description and Operation > Pinch Sensor - Description > Page 9442 Power Trunk / Liftgate Hazard Sensor: Description and Operation Pinch Sensor - Operation OPERATION During a power liftgate "close" cycle, if either of the two conductive rubber strips (tapeswitch) of the pinch sensor come in contact with an obstacle, the pinch sensor circuit is completed. This tells the power liftgate control module that a obstruction is felt. The control module will stop the liftgate immediately and return it to the full open position. The thermistor portion of the right pinch sensor provides the temperature signal to the power liftgate control module (temperature is provided when the pinch sensor is in an unpinched condition; when pinched, temperature is unavailable because the thermistor is shorted). As the outside temperature increases, the resistance reading decreases. As temperature decreases, the resistance reading increases. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Description and Operation > Page 9443 Power Trunk / Liftgate Hazard Sensor: Testing and Inspection RIGHT PINCH SENSOR/THERMISTOR The thermistor portion of the right pinch sensor provides the temperature signal to the power liftgate control module (temperature is provided when the pinch sensor is in an unpinched condition; when pinched, temperature is unavailable because the thermistor is shorted). Refer to the RIGHT PINCH SENSOR/THERMISTOR DIAGNOSTIC TABLE to test the thermistor resistance. RIGHT PINCH SENSOR/THERMISTOR DIAGNOSTIC TABLE Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Service and Repair > Pinch Sensor - Removal Power Trunk / Liftgate Hazard Sensor: Service and Repair Pinch Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove trim panel from liftgate, See: Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal. 3. Disconnect the pinch sensor wire harness connector (4). 4. Remove the clips/assembly holding the pinch sensor (2) to liftgate (1). 5. Feed the pinch sensor wire harness (5) out of the liftgate (1) and remove the sensor (2) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Hazard Sensor > Component Information > Service and Repair > Pinch Sensor - Removal > Page 9446 Power Trunk / Liftgate Hazard Sensor: Service and Repair Pinch Sensor - Installation INSTALLATION WARNING: Use extreme caution when testing pinch sensor operation. 1. Route the pinch sensor wire harness (5) through the hole in the liftgate (1). Push the wire harness grommet into place until fully seated. 2. Position the pinch sensor (2) to the liftgate (1) and align the holes to the fastening clips. 3. Install the four clips holding the sensor to the liftgate. 4. Connect the pinch sensor wire harness connector (4). 5. Install the trim panel on the liftgate, See: Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Installation. 6. Connect the battery negative cable. 7. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes related to the pinch sensor. 8. Verify power liftgate system and pinch sensor operation. Cycle the power liftgate through one complete open and close cycle, during the final close cycle press the pinch sensor to verify the power liftgate detects an obstruction and returns to the full open position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Driver Heated Seat Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Driver Heated Seat Switch > Page 9451 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Heated Seat Switch (Instrument Panel) 6 Way Seat Heater Switch: Diagrams Driver Heated Seat Switch (Instrument Panel) 6 Way Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-HEATED SEAT-DRIVER - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Heated Seat Switch (Instrument Panel) 6 Way > Page 9454 Seat Heater Switch: Diagrams Left Rear Heated Seat Switch (Rear Seat) 6 Way Connector - (REAR SEAT) 6 WAY SWITCH-HEATED SEAT-LEFT REAR - (REAR SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Heated Seat Switch (Instrument Panel) 6 Way > Page 9455 Seat Heater Switch: Diagrams Passenger Heated Seat Switch (Instrument Panel) 6 Way Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-HEATED SEAT-PASSENGER - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Diagrams > Driver Heated Seat Switch (Instrument Panel) 6 Way > Page 9456 Seat Heater Switch: Diagrams Right Rear Heated Seat Switch (Rear Seat) 6 Way Connector - (REAR SEAT) 6 WAY SWITCH-HEATED SEAT-RIGHT REAR - (REAR SEAT) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description Seat Heater Switch: Description and Operation Heated Seat Switch - Description Front DESCRIPTION The heated seat switches are both mounted in the instrument panel. The two switches are snapped into mounting holes in the instrument panel center bezel (1). The two heated seat switches (2) and (3) are identical in appearance and construction, except for the location of a keyway in the connector receptacle on the back of each switch. The instrument panel wire harness connectors for the heated seat switches are keyed to match the connector receptacles so that the two heated seat switches can only be connected to the proper heated seat. Each momentary, bidirectional rocker-type heated seat switch provides a resistor-multiplexed signal to the Cab Compartment Node (CCN). Each switch has a center neutral position and momentary Low and High positions so that the driver and the front seat passenger can select a preferred seat heating level. Each heated seat switch has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Each switch also has one indicator lamp for back lighting of the switch when the ignition switch is in the Run position. The five LED indicator lamps in each heated seat switch cannot be repaired. If the LED lamps are faulty or damaged, or the switch is faulty or damaged the individual heated seat switch assembly must be replaced. Second Row DESCRIPTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description > Page 9459 Momentary contact push button switch/modules (2) mounted in the front face of the second row center floor console (3) operate the heated second row seat system. Each heated seat switch/module has two Light-Emitting Diode (LED) indicator lamps, which indicate the selected level (Low or High) of the seat heater. Pressing the switch/module button initiates heat. Heat remains on until switched off or until the ignition is turned off. If switched off by the ignition, a switch/module button must be pressed to restart heating. The switch/modules contain the solid state electronic control and diagnostic logic circuitry for the heated second row seat system. If any of the heated second row seat elements are inoperative or damaged one or more of the LED lamps in the switch/module for the effected seat will flash. The LED indicator lamps in each heated seat switch/module cannot be repaired. If the LED lamps are inoperative or damaged, or the switch/module is inoperative or damaged the individual heated seat switch/module assembly must be replaced. See: Service and Repair/Heated Seat Switch Removal for the switch/module replacement procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Heated Seat Switch - Description > Page 9460 Seat Heater Switch: Description and Operation Heated Seat Switch - Operation Front OPERATION The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. Depressing the heated seat switch rocker to its momentary High or Low position provides a hard-wired resistor multiplexed signal to the Cabin Compartment Node (CCN). The CCN is responsible for supplying the CAN bus message to the heated seat module, signaling the module to power the heated seat element of the selected seat and maintain the temperature setting. If the heated seat switch is depressed to a different position (Low or High) than the currently selected state, the CCN will go through the process again to change the temperature setting. If a heated seat switch is depressed a second time to the same position as the currently selected state, the CCN and heated seat module interprets the second input as a request to turn the seat heater OFF. The CCN will then signal the heated seat module to turn the heated seat elements for that seat off. The backlighting LED's in each of the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The ground side of the indicator lamp is divided by a separate lamp driver circuit in the CCN. Second Row OPERATION A Heated Seat Switch/Module is used to control the heated second row seat system. The heated seat switch/modules receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The switch/module responds to heated seat switch/module button input and ignition switch status inputs by controlling the 12v output to the front seat heating elements through integral solid-state relays. When either of the heated seat switch/module buttons are depressed the heating element for the selected seat is energized. Amber Light Emitting Diodes (LEDS) on the side of each switch/module indicate the level of heat in use: Two LEDs are illuminated for high, one for low, and none for off. Pressing the switch/module button once will select high-level heating. Pressing the button a second time will select low-level heating. Pressing the button a third time will shut the heating elements off. The heated seat switch/module energizes an integral solid-state relay, which supplies battery current to the heating elements. When high-temperature heating is selected, the heaters provide a boosted heat level during the first four minutes of operation after heating is activated. The heat output then drops to the normal high-temperature level. If high-level heating is selected, the control system will automatically switch to the low level after thirty minutes of continuous operation. At that time, the number of illuminated LEDs changes from two to one, indicating the change. Operation on the low setting will continue for another thirty minutes and the system will then be automatically turned off. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Description and Operation > Page 9461 Seat Heater Switch: Testing and Inspection HEATED SEAT SWITCH Refer to the Wiring section for complete heated seat system wiring diagrams. WARNING: Disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental airbag deployment and possible personal injury. 1. If the problem being diagnosed involves inoperative heated seat switch back lighting and the heated seat elements do heat, disconnect the inoperative switch and check for continuity between the ground pin at the heated seat switch connector and ground. If there is no continuity, repair an open wire between ground and the heated seat switch connector. If there is continuity, replace the inoperative heated seat switch. If the problem being diagnosed involves a heated seat switch indicator lamp that remains illuminated after the heated seat has been turned Off, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Also refer to the Body Diagnostic Information for additional diagnosis and testing procedures. 2. Check the fused ignition switch output (run) fuse in the Power Distribution Center (PDC). If OK, go to 3. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. 3. Turn the ignition switch to the On position. Check for battery voltage at the fused ignition switch output (run) fuse in the PDC. If OK, go to 4. If not OK, repair the open fused ignition switch output (run) circuit to the ignition switch as required. 4. Disconnect and isolate the battery negative cable. Disconnect the wire harness connector from the connector receptacle on the back of the heated seat switch to be tested. Reconnect the battery negative cable. Turn the ignition switch to the Run position. Check for battery voltage at the fused ignition switch output (run) circuit cavity of the heated seat switch. If OK, go to 5. If not OK, repair the open fused ignition switch output (run) circuit to the PDC fuse as required. 5. Check the continuity and resistance values of the heated seat switch in the Neutral, Low and High positions as shown in the Heated Seat Switch Continuity chart below. If OK, See: Relays and Modules - Body and Frame/Seat Heater Control Module/Testing and Inspection. Also refer to the Body Diagnostic Information for additional diagnosis and testing procedures. If not OK, replace the faulty heated seat switch. HEATED SEAT SWITCH CONTINUITY CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal Seat Heater Switch: Service and Repair Heated Seat Switch - Removal Front REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Remove the center bezel (1) from the instrument panel See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the heated seat switch bezel and both switches from the center bezel as a unit. 4. From the back of the heated seat switch bezel (2), gently pry the switch free and push the heated seat switch out through the rear of the bezel. Second Row REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 9464 1. Disconnect and isolate the battery negative cable. 2. Using an appropriate flat bladed tool, remove the heated seat switch/modules (2) from the rear center floor console (3) by gently prying up from the edge of the switch/module bezel (1). Take care not to scratch or damage the console or bezel in any way. 3. Disconnect the switch/module electrical connectors (2) and (4). 4. Using an appropriate flat bladed tool, remove the heated seat switch/module (3) from the bezel (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 9465 Seat Heater Switch: Service and Repair Heated Seat Switch - Installation Front INSTALLATION NOTE: When installing the heated seat switches, be certain they are installed in the proper mounting holes of the heated seat switch bezel (2). The heated seat switches are identified by a keyway in the connector receptacle on the back of each switch. 1. From the back of the heated seat switch bezel, gently push the heated seat switch in through the rear of the bezel. 2. Install the center bezel on the instrument panel See: Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Cluster Bezel - Installation. 3. Connect the battery negative cable. 4. Verify heated seat system operation. Second Row INSTALLATION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Heated Seat Switch - Removal > Page 9466 1. Align the tabs (1) of the switch/module (2) to the bezel and gently push together until the tabs are securely in place. 2. Connect the switch/module electrical connectors (2) and (4). 3. Gently push the heated seat switch/module bezel (1) into the mounting hole in the center console (3) until it is securely in place. 4. Connect the battery negative cable. 5. Verify heated seat system operation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch > Component Information > Locations > Page 9470 Seat Memory Switch: Diagrams Connector - (LEFT FRONT DOOR) 6 WAY SWITCH-MEMORY SELECTOR - (LEFT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Sunroof Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations > Sunroof Switch > Page 9475 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Sunroof Switch (Headliner) 4 Way Sunroof / Moonroof Switch: Diagrams Sunroof Switch (Headliner) 4 Way Connector - (HEADLINER) 4 WAY SWITCH-SUNROOF - (HEADLINER) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Sunroof Switch (Headliner) 4 Way > Page 9478 Sunroof / Moonroof Switch: Diagrams Sunroof/Power Liftgate Switch (Headliner) 6 Way Connector - (HEADLINER) 6 WAY SWITCH-SUNROOF/LIFTGATE PLG - (HEADLINER) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Power Top Switch - Removal Sunroof / Moonroof Switch: Service and Repair Power Top Switch - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Separate the overhead console from the headliner, by carefully pulling down on the front portion, toward the windshield, to release the retaining clips. 3. Release the sunroof switch retaining tab (2), disconnect the electrical connector (1) and remove the switch from the console. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Power Top Switch - Removal > Page 9481 Sunroof / Moonroof Switch: Service and Repair Power Top Switch - Installation INSTALLATION 1. Position the switch (2) against the overhead console (1) and push the switch to seat properly in retaining clip (3). 2. Install the overhead console and seat the retaining clips (4) fully. 3. Connect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Locations > Page 9485 Trunk / Liftgate Ajar Switch: Diagrams Connector - (LIFTGATE) 2 WAY SWITCH-LIFTGATE AJAR - (LIFTGATE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Description and Operation > Liftgate Ajar Switch - Description Trunk / Liftgate Ajar Switch: Description and Operation Liftgate Ajar Switch - Description LIFTGATE A liftgate ajar switch is standard equipment on this vehicle. The switch is concealed within and integral to the liftgate latch unit. The switch is a momentary leaf contact-type unit that is actuated by the liftgate latch mechanisms. An integral connector receptacle on the liftgate latch connects the liftgate ajar switch to the vehicle electrical system through the liftgate wire harness. The liftgate ajar switch cannot be adjusted or repaired and, if ineffective or damaged, the liftgate latch unit must be replaced. See: Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/Removal and Replacement/Latch - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Description and Operation > Liftgate Ajar Switch - Description > Page 9488 Trunk / Liftgate Ajar Switch: Description and Operation Liftgate Ajar Switch - Operation LIFTGATE The liftgate ajar switch is actuated by the liftgate latch mechanism. When the liftgate is closed and properly latched, its liftgate ajar switch is an open circuit. When the liftgate is open or only partially latched, the liftgate ajar switch is a closed circuit. The liftgate ajar switch is hard wired in series between a body ground and the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC reads the hard wired liftgate ajar switch input through an internal pull-up, then uses this input to control many electronic functions and features of the vehicle. The liftgate ajar switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Power Liftgate Release Switch (Except Sunroof) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Power Liftgate Release Switch (Except Sunroof) > Page 9493 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Power Liftgate Release Switch (Headliner) 4 Way Trunk / Liftgate Switch: Diagrams Power Liftgate Release Switch (Headliner) 4 Way Connector - (HEADLINER) 4 WAY SWITCH-LIFTGATE RELEASE PLG - (HEADLINER) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Power Liftgate Release Switch (Headliner) 4 Way > Page 9496 Trunk / Liftgate Switch: Diagrams Sunroof/Power Liftgate Switch (Headliner) 6 Way Connector - (HEADLINER) 6 WAY SWITCH-SUNROOF/LIFTGATE PLG - (HEADLINER) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch - Installation Trunk / Liftgate Switch: Description and Operation Exterior Handle Switch - Installation DESCRIPTION All vehicles are equipped with a power liftgate exterior handle switch. The switch is integral to the power liftgate latch assembly. It is activated by the exterior handle, located in the license plate light bar, through a mechanical link rod attaching the two together. The power liftgate exterior handle switch is primarily used for manual opening of the liftgate. Activation of the switch during a automatic power "close" cycle will cause the liftgate to reverse direction. Activation of the switch during a power "open" cycle will cause the power liftgate to disengage, allowing full manual operation. The exterior handle cannot be adjusted or repaired and if damaged it must be replaced. See: Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Handle/Service and Repair/Exterior Handle - Removal. The power liftgate exterior handle switch cannot be adjusted or repaired and if damaged or inoperative the complete power liftgate latch assembly must be replaced. See: Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Latch/Service and Repair/Removal and Replacement/Power Liftgate Latch - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch - Installation > Page 9499 Trunk / Liftgate Switch: Description and Operation Exterior Handle Switch - Removal OPERATION When the exterior liftgate handle is pulled, a mechanical linkage inside the liftgate depresses the power liftgate exterior handle switch in the power liftgate latch assembly. A hard-wired signal is then detected by the Power Liftgate Control Module. The power liftgate control module then looks at the vehicle lock status on the Controller Area Network (CAN) data bus. If the vehicle is not locked and the operating conditions are met, the power liftgate control module then applies power to the latch mounted motor, which moves the liftgate from the primary closed and latched position to the open and movable position. If the liftgate is not pulled open within seven seconds, once the latch releases, the latch will automatically cinch closed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch - Installation > Page 9500 Trunk / Liftgate Switch: Description and Operation Overhead Console Switch - Description DESCRIPTION NOTE: The overhead console shown contains a combination power liftgate/power sunroof switch. Vehicles equipped with the power liftgate and no sunroof contain a single power liftgate switch only. NOTE: On vehicles equipped with both a power sunroof and power liftgate the overhead console switches are serviced together as one assembly. NOTE: Durango overhead console with Electronic Vehicle Information Center (EVIC) shown. Aspen overhead console similar. The power liftgate switch (3) is mounted in the overhead console assembly (1) between the reading lamps (2). The switch is snapped into mounting slots in the overhead console assembly. The momentary, push button-type power liftgate switch, provides a hardwired signal to the Power Liftgate Control Module. If the switch is inoperative or damaged the power liftgate/power sunroof switch assembly must be replaced. See: Service and Repair/Overhead Console Switch - Removal for the appropriate procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Description and Operation > Exterior Handle Switch - Installation > Page 9501 Trunk / Liftgate Switch: Description and Operation Overhead Console Switch - Operation OPERATION Battery voltage is supplied to the power liftgate system through a fuse, located in the Integrated Power Module (IPM) assembly. When the power liftgate switch is pushed, a hardwired signal is sent to the Power Liftgate Control Module. The power liftgate control module then interprets the information to confirm safety requirements are met before applying power to the power liftgate drive unit to start a power cycle. During a power liftgate open or close cycle, if the power liftgate control module detects sufficient resistance to liftgate travel, such as an obstruction in the liftgate's path. The control module will immediately stop liftgate movement and reverse the direction of travel to the full open or closed position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Description and Operation > Page 9502 Trunk / Liftgate Switch: Testing and Inspection OVERHEAD CONSOLE LIFTGATE SWITCH Diagnostic resistors are present inside the overhead console liftgate switch. These resistors are used by the power liftgate control module to determine if the switch is stuck, disconnected, shorted or otherwise damaged. Refer to the OVERHEAD CONSOLE LIFTGATE SWITCH DIAGNOSTIC TABLE to test the switch resistance. OVERHEAD CONSOLE LIFTGATE SWITCH DIAGNOSTIC TABLE NOTE: Test table readings are ± 2%. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Overhead Console Switch - Removal Trunk / Liftgate Switch: Service and Repair Overhead Console Switch - Removal REMOVAL DURANGO 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console assembly (3), See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Using trim stick C-4755 or equivalent, pry the back edge of the power liftgate switch (1) up until the two retaining tabs (2) are fully released. 4. Tilt the power liftgate switch (1) up away from the overhead console assembly (3) until the mounting tab on the opposite side of the switch releases. 5. Remove the switch from the vehicle. ASPEN 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console assembly (3), See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Using trim stick C-4755 or equivalent, pry the side edges (4) of the overhead console assembly out until the two retaining tabs on the power liftgate switch (5) are fully released. 4. Push the switch (5) out through the back of the overhead console (3). 5. Remove the switch from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Overhead Console Switch - Removal > Page 9505 Trunk / Liftgate Switch: Service and Repair Overhead Console Switch - Installation INSTALLATION DURANGO 1. Position the power liftgate switch into the overhead console assembly so that the large retaining tab (2) is aligned with the large slot between the reading lamps. 2. Gently press the power liftgate switch (1) into the overhead console assembly (3) until the two small mounting tabs (2) have snapped securely into place. 3. Install the overhead console assembly (3), See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Installation. 4. Connect the battery negative cable. 5. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes. 6. Verify power liftgate system operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. ASPEN Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Service and Repair > Overhead Console Switch - Removal > Page 9506 1. Position the power liftgate switch (5) into the overhead console assembly (3). 2. Gently press the power liftgate switch (5) into the overhead console assembly (3) until the mounting tabs have snapped securely into place (4). 3. Install the overhead console assembly (3), See: Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Installation. 4. Connect the battery negative cable. 5. Using an appropriate scan tool, check and erase any power liftgate control module diagnostic trouble codes. 6. Verify power liftgate system operation. Cycle the power liftgate through one complete open and close cycle, this will allow the power liftgate control module to relearn its cycle with the new components. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations Sound Proofing / Insulation: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9510 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9511 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9512 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9513 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9514 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9515 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9516 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9517 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9518 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9519 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9520 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9521 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9522 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9523 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9524 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9525 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9526 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Locations > Page 9527 BODY SOUND DEADENER LOCATIONS Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Spare Tire Carrier > Component Information > Service and Repair > Spare Tire Carrier Winch - Removal Spare Tire Carrier: Service and Repair Spare Tire Carrier Winch - Removal REMOVAL 1. Pull up on the hole (1) cut in the carpet (2) to access the spare tire winch cover. 2. Remove the spare tire winch cover (1). 3. Install the jack handle (2) and lug wrench (1) to the spare tire winch (3) to loosen the spare tire to the ground. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Spare Tire Carrier > Component Information > Service and Repair > Spare Tire Carrier Winch - Removal > Page 9532 4. Remove spare tire. 5. Remove 4 bolts (1) attaching spare tire winch (2) to body (3). 6. Separate spare tire winch from vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Spare Tire Carrier > Component Information > Service and Repair > Spare Tire Carrier Winch - Removal > Page 9533 Spare Tire Carrier: Service and Repair Spare Tire Carrier Winch - Installation INSTALLATION 1. Position spare tire winch (2) on the vehicle. 2. Install and tighten 4 bolts (1) attaching the spare tire winch to body (3). 3. Install spare tire. 4. Tighten the spare tire up to the vehicle. 5. Remove the jack handle (2) and lug wrench (1). 6. Install the spare tire winch cover (1) and reseat the carpet access hole. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair > Tow Hook(s) - Removal Towing Hook / Bracket: Service and Repair Tow Hook(s) - Removal REMOVAL 1. Remove the front body mount bolt (1). 2. Remove the nuts (3) and remove the tow hook. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Towing Hook / Bracket > Component Information > Service and Repair > Tow Hook(s) - Removal > Page 9538 Towing Hook / Bracket: Service and Repair Tow Hook(s) - Installation INSTALLATION 1. Install the support brackets and install the bumper support nuts (3). 2. Tighten the nuts (3) to 109 Nm (80 ft. lbs.). 3. Install the front body mount bolt (1) and tighten to 81 Nm (60 ft. lbs.). 4. Install the support bracket (2) nuts (3) and tighten to 109 Nm (80 ft. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Cowl Panel Cover - Removal Cowl Moulding / Trim: Service and Repair Cowl Panel Cover - Removal REMOVAL 1. Open the hood and remove the wiper arm nuts (3) and wiper arms (2). See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 2. Remove the two rear screws (1) and the five front push pins (5). 3. Remove the cowl grille (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Door Weatherstrip - Removal Front Door Weatherstrip: Service and Repair Door Weatherstrip - Removal REMOVAL 1. Insert special tool #9093 (2) between the outer belt molding (1) and glass at the rear. 2. Push down on outer belt molding (1) and rotate upper part of tool (2) outward from vehicle then lift up on molding (1) to disengage from locking tabs (3) working from back to front. NOTE: Typical outer belt molding design shown. 3. Slide molding out from under the side view mirror and remove. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Door Weatherstrip - Removal > Page 9550 Front Door Weatherstrip: Service and Repair Door Weatherstrip - Installation INSTALLATION 1. Position the outer belt molding onto the door and position forward under the side view mirror. Seat the molding fully. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Front Door Glass Run Weatherstrip - Removal Front Door Window Glass Weatherstrip: Service and Repair Front Door Glass Run Weatherstrip Removal REMOVAL 1. Remove glass. See: Doors, Hood and Trunk/Doors/Front Door/Front Door Window Glass/Service and Repair/Front Door Glass - Removal 2. Pull the glass run weatherstrip and run channels from the window opening. 3. Pull the glass run weatherstrip from the run channels. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Inner Belt Weatherstrip - Installation Rear Door Weatherstrip: Service and Repair Rear Door Inner Belt Weatherstrip - Installation INSTALLATION 1. Position weatherstrip on inner door panel. 2. Press into place. 3. Install trim panel. See: Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Inner Belt Weatherstrip - Installation > Page 9559 Rear Door Weatherstrip: Service and Repair Rear Door Outer Belt Weatherstrip - Removal REMOVAL 1. Insert special tool #9093 (2) between the outer belt molding (1) and glass at the rear. 2. Push down on outer belt molding (1) and rotate upper part of tool (2) outward from vehicle then lift up on molding (1) to disengage from locking tabs (3) working from back to front. NOTE: Typical outer belt molding design shown. 3. Slide molding out from under the side view mirror and remove. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Rear Door Inner Belt Weatherstrip - Installation > Page 9560 Rear Door Weatherstrip: Service and Repair Rear Door Outer Belt Weatherstrip - Installation INSTALLATION 1. Position the outer belt molding onto the door and seat the molding fully starting at the back of the door. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Left Speed Control Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Left Speed Control Switch > Page 9566 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Left Speed Control Switch (Steering Wheel) 3 Way Cruise Control Switch: Diagrams Left Speed Control Switch (Steering Wheel) 3 Way Connector - (STEERING WHEEL) 3 WAY SWITCH-SPEED CONTROL-LEFT - (STEERING WHEEL) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Left Speed Control Switch (Steering Wheel) 3 Way > Page 9569 Cruise Control Switch: Diagrams Right Speed Control Switch (Steering Wheel) 3 Way Connector - (STEERING WHEEL) 3 WAY SWITCH-SPEED CONTROL-RIGHT - (STEERING WHEEL) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Speed Control Switch - Description Cruise Control Switch: Description and Operation Speed Control Switch - Description DESCRIPTION Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the Owner's Manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Speed Control Switch - Description > Page 9572 Cruise Control Switch: Description and Operation Speed Control Switch - Operation OPERATION When speed control is selected by depressing the ON, OFF switch, the PCM allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 (56.2kph) and 85 mph (136.8kph). In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph (16 kph) per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph (16 kph) per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph (32.1 kph) of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's RAM when the ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph (3.2 kph) for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's ON, OFF input, and the battery voltage to the brake switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal Cruise Control Switch: Service and Repair Speed Control Switch - Removal REMOVAL WARNING: Before attempting to diagnose, remove or install any airbag system or related steering wheel and steering column components you must first disconnect and isolate the negative (ground) battery cable. Wait 2 minutes for system capacitor to discharge before further system service. Failure to do so could result in accidental deployment and possible personal injury. 1. Disconnect and isolate negative battery cable from battery. 2. Remove airbag module. 3. Unplug electrical connector. 4. Remove speed control switch mounting screw (1) and remove switch from steering wheel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal > Page 9575 Cruise Control Switch: Service and Repair Speed Control Switch - Installation INSTALLATION 1. Position switch to steering wheel. 2. Install switch mounting screw and tighten to 15 in. lbs. (1.7 Nm). 3. Plug electrical connector into switch. 4. Install airbag module. 5. Connect negative battery cable to battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Left Speed Control Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Left Speed Control Switch > Page 9581 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Left Speed Control Switch (Steering Wheel) 3 Way Cruise Control Switch: Diagrams Left Speed Control Switch (Steering Wheel) 3 Way Connector - (STEERING WHEEL) 3 WAY SWITCH-SPEED CONTROL-LEFT - (STEERING WHEEL) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Diagrams > Left Speed Control Switch (Steering Wheel) 3 Way > Page 9584 Cruise Control Switch: Diagrams Right Speed Control Switch (Steering Wheel) 3 Way Connector - (STEERING WHEEL) 3 WAY SWITCH-SPEED CONTROL-RIGHT - (STEERING WHEEL) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Speed Control Switch - Description Cruise Control Switch: Description and Operation Speed Control Switch - Description DESCRIPTION Two separate switch pods operate the speed control system. The steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON, OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the Owner's Manual for more information on speed control switch functions and setting procedures. The individual switches cannot be repaired. If one switch fails, the entire switch module must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Description and Operation > Speed Control Switch - Description > Page 9587 Cruise Control Switch: Description and Operation Speed Control Switch - Operation OPERATION When speed control is selected by depressing the ON, OFF switch, the PCM allows a set speed to be stored in its RAM for speed control. To store a set speed, depress the SET switch while the vehicle is moving at a speed between approximately 35 (56.2kph) and 85 mph (136.8kph). In order for the speed control to engage, the brakes cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral. The speed control can be disengaged manually by: - Stepping on the brake pedal - Depressing the OFF switch - Depressing the CANCEL switch. The speed control can be disengaged also by any of the following conditions: - An indication of Park or Neutral (auto. trans.) - The VSS signal increases at a rate of 10 mph (16 kph) per second (indicates that the co-efficient of friction between the road surface and tires is extremely low) - Depressing the clutch pedal (manual trans.). - Excessive engine rpm (indicates that the transmission may be in a low gear) - The VSS signal decreases at a rate of 10 mph (16 kph) per second (indicates that the vehicle may have decelerated at an extremely high rate) - If the actual speed is not within 20 mph (32.1 kph) of the set speed The previous disengagement conditions are programmed for added safety. Once the speed control has been disengaged, depressing the ACCEL switch restores the vehicle to the target speed that was stored in the PCM's RAM NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM. If, while the speed control is engaged, the driver wishes to increase vehicle speed, the PCM is programmed for an acceleration feature. With the ACCEL switch held closed, the vehicle accelerates slowly to the desired speed. The new target speed is stored in the PCM's RAM when the ACCEL switch is released. The PCM also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph (3.2 kph) for each momentary switch activation of the ACCEL switch. The PCM also provides a means to decelerate without disengaging speed control. To decelerate from an existing recorded target speed, depress and hold the COAST switch until the desired speed is reached. Then release the switch. The ON, OFF switch operates two components: the PCM's ON, OFF input, and the battery voltage to the brake switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal Cruise Control Switch: Service and Repair Speed Control Switch - Removal REMOVAL WARNING: Before attempting to diagnose, remove or install any airbag system or related steering wheel and steering column components you must first disconnect and isolate the negative (ground) battery cable. Wait 2 minutes for system capacitor to discharge before further system service. Failure to do so could result in accidental deployment and possible personal injury. 1. Disconnect and isolate negative battery cable from battery. 2. Remove airbag module. 3. Unplug electrical connector. 4. Remove speed control switch mounting screw (1) and remove switch from steering wheel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Service and Repair > Speed Control Switch - Removal > Page 9590 Cruise Control Switch: Service and Repair Speed Control Switch - Installation INSTALLATION 1. Position switch to steering wheel. 2. Install switch mounting screw and tighten to 15 in. lbs. (1.7 Nm). 3. Plug electrical connector into switch. 4. Install airbag module. 5. Connect negative battery cable to battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations > Page 9594 Vacuum Brake Booster Diaphragm Position Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 3 WAY SENSOR-BOOSTER TRAVEL (HEV) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Description DESCRIPTION The travel sensor (7) is mounted on power brake booster (1) below and to the left of the master cylinder, and has one electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description > Page 9597 Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Operation OPERATION The travel sensor is a three-wire potentiometer that varies the voltage output as the position of the booster diaphragm changes. The RBS module uses the position information to determine the amount of booster movement and hydraulic brake application. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor - Removal REMOVAL 1. Disconnect the electrical connector (2) from the travel sensor (1). NOTE: The retainer clip does not need to be removed, only pushed up slightly to disengage the tabs on the sensor. 2. Using a small screw driver (4) or another suitable tool, push up on the retainer clip (2) and pull the travel sensor (3) from the power brake booster (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal > Page 9600 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor Installation INSTALLATION NOTE: When replacing the travel sensor, the Anti-Lock Brake Module (ABM) must be initialized using the scan tool. To initialize the ABM perform the ABS VERIFICATION TEST - HEV. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test . NOTE: Verify that the surface is clean, the old O-ring is removed, and the new O-ring is properly positioned on the sensor. 1. With a slight twisting motion, push the travel sensor (3) into the power brake booster (1). There should be a slight snapping sound as the retainer clip (3) seats into position. 2. Verify that the travel sensor retainer clip (3) snapped into place. 3. Connect the electrical connector (2) to the travel sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Locations > Page 9604 Vacuum Brake Booster Diaphragm Position Sensor: Diagrams Connector (HEV) - (HEADLAMP AND DASH) 3 WAY SENSOR-BOOSTER TRAVEL (HEV) - (HEADLAMP AND DASH) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Description DESCRIPTION The travel sensor (7) is mounted on power brake booster (1) below and to the left of the master cylinder, and has one electrical connector. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Description and Operation > Travel Sensor - Description > Page 9607 Vacuum Brake Booster Diaphragm Position Sensor: Description and Operation Travel Sensor Operation OPERATION The travel sensor is a three-wire potentiometer that varies the voltage output as the position of the booster diaphragm changes. The RBS module uses the position information to determine the amount of booster movement and hydraulic brake application. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor - Removal REMOVAL 1. Disconnect the electrical connector (2) from the travel sensor (1). NOTE: The retainer clip does not need to be removed, only pushed up slightly to disengage the tabs on the sensor. 2. Using a small screw driver (4) or another suitable tool, push up on the retainer clip (2) and pull the travel sensor (3) from the power brake booster (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Cruise Control > Vacuum Brake Booster Diaphragm Position Sensor > Component Information > Service and Repair > Travel Sensor - Removal > Page 9610 Vacuum Brake Booster Diaphragm Position Sensor: Service and Repair Travel Sensor Installation INSTALLATION NOTE: When replacing the travel sensor, the Anti-Lock Brake Module (ABM) must be initialized using the scan tool. To initialize the ABM perform the ABS VERIFICATION TEST - HEV. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/ABS Verification Test . NOTE: Verify that the surface is clean, the old O-ring is removed, and the new O-ring is properly positioned on the sensor. 1. With a slight twisting motion, push the travel sensor (3) into the power brake booster (1). There should be a slight snapping sound as the retainer clip (3) seats into position. 2. Verify that the travel sensor retainer clip (3) snapped into place. 3. Connect the electrical connector (2) to the travel sensor (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > ABS Indicator - Description ABS Light: Description and Operation ABS Indicator - Description DESCRIPTION An Antilock Brake System (ABS) indicator is standard equipment on all instrument clusters. This indicator serves both the standard equipment Rear Wheel Anti-Lock (RWAL) and optional equipment 4-Wheel Anti-Lock (4WAL) brake systems. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The ABS indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Failure of Anti-lock Braking System in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ABS indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation > ABS Indicator - Description > Page 9616 ABS Light: Description and Operation ABS Indicator - Operation OPERATION The ABS indicator gives an indication to the vehicle operator when the ABS system, or a circuit or component of the system is ineffective. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus. The ABS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the ABS indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the ABS indicator illuminates for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - ABS Indicator Lamp-On Message - Each time the cluster receives an electronic ABS indicator lamp-on message from the CAB, the ABS indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch turns to the OFF position, whichever occurs first. Communication Error - If the cluster receives no lamp-on or lamp-off messages from the CAB for five consecutive message cycles, the ABS indicator illuminates. The indicator remains illuminated until the cluster receives a valid message from the CAB, or until the ignition switch turns to the OFF position, whichever occurs first. - Self Test - Each time the instrument cluster is put through the self test, the ABS indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - ABS Diagnostic Test - The ABS indicator blinks on and off by lamp-on and lamp-off messages from the CAB during the performance of the ABS diagnostic tests. The CAB continually monitors the ABS circuits and sensors to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a system malfunction or that the ABS system has become ineffective. The CAB stores a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ABS indicator fails to light due to an open or short in the cluster ABS indicator circuit, the cluster sends a message notifying the CAB of the condition, then the instrument cluster and the CAB each store a DTC. Use a diagnostic scan tool for proper diagnosis of the antilock brake system, the CAB, the CCN, the CAN data bus or the electronic communication related to ABS indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Chime/Buzzer - Description Audible Warning Device: Description and Operation Chime/Buzzer - Description Chime Warning System CHIME WARNING SYSTEM A chime warning system is standard factory-installed equipment. The chime warning system uses an electromechanical transducer and an electromechanical relay that are soldered onto the electronic circuit board of the instrument cluster (1). This warning system provides audible indications of various vehicle conditions that may require the attention of the vehicle operator or occupants. The instrument cluster also includes the hardware and software necessary to serve as the electronic body control module and is sometimes referred to as the Cab Compartment Node (CCN). The electromechanical transducer generates beep tones and chime tones, while the electromechanical relay generates click tones to emulate the sounds associated with conventional turn signal and hazard warning flasher operation. The microprocessor-based CCN uses electronic chime request messages received from other modules in the vehicle over the Controller Area Network (CAN) data bus, along with hardwired inputs to monitor many sensors and switches throughout the vehicle. In response to those inputs, the circuitry and programming of the CCN allow it to control the audible outputs that are produced through its on-board transducer and relay. The CCN is capable of producing the following audible outputs: - Slow-Rate Repetitive Click - Repeated click tones generated at a rate of 50 clicks per minute. - Fast-Rate Repetitive Click - Repeated click tones generated at a rate of 100 clicks per minute. - Fixed Duration Beep - A short, sharp, single beep tone. - Single Chime Tone - A single chime tone. - Slow-Rate Repetitive Chime - Repeated chime tones generated at a rate of 50 chimes per minute. Fast-Rate Repetitive Chime - Repeated chime tones generated at a rate of 180 chimes per minute. Hardwired circuitry connects the CCN and the various chime warning system switch and sensor inputs to their modules and to each other through the electrical system of the vehicle. These hardwired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other, to the vehicle electrical system and to the CCN through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. The CCN chime warning system circuits and components cannot be adjusted or repaired. If any of the circuitry, the on-board transducer or the relay are damaged or ineffective, the instrument cluster assembly must be replaced. Park Assist System Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Chime/Buzzer - Description > Page 9621 PARK ASSIST SYSTEM A park assist system is an optional factory-installed electronic parking aid. During parking and other similar vehicle maneuvers this system alerts the vehicle operator to obstacles located in the path immediately behind the vehicle which, due to the surrounding rear vehicle structure, might be otherwise difficult to perceive. When an object is detected, the system uses an electromechanical transducer and Light Emitting Diode (LED) indicators within the park assist display unit to provide the vehicle operator with visual and audible indications of the presence and proximity of such objects. The park assist system includes the following major components, which are described in further detail elsewhere in this service information: - Electronic Vehicle Information Center (1) - In vehicles equipped with the optional park assist system, the Electronic Vehicle Information Center (EVIC) in the overhead console displays textual warnings and error messages and emits audible warnings related to the current operating status of the park assist system and provides an interface that allows the vehicle operator to manually disable or enable the system using the customer programmable features option. - Park Assist Display (3) - Vehicles equipped with the park assist system have a park assist display unit mounted in the rear of the headliner just forward of the liftgate opening. The body of the display is concealed above the headliner where it is secured by a retainer on the back of the headliner substrate. Only the narrow, oval-shaped smoked clear lens of the display is visible on the outer surface of the headliner. - Park Assist Module (2) - Vehicles equipped with the park assist system include a park assist module which is secured through integral mounting tabs by push-in type fasteners to the quarter inner panel above the left rear wheel housing where it is concealed beneath the quarter inner trim panel. - Park Assist Sensors (4) - Vehicles equipped with the park assist system have four ultrasonic park assist sensors that are concealed behind the rear bumper fascia. Each sensor is snapped into an individual molded plastic mounting bracket located at horizontal intervals along the back side of the rear bumper fascia. Hard wired circuitry connects the various park assist system components to each other through the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other and to the vehicle electrical system through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. The park assist system components cannot be adjusted or repaired. If any of the park assist system components is damaged or ineffective, that component must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Chime/Buzzer - Description > Page 9622 Audible Warning Device: Description and Operation Chime/Buzzer - Operation Chime Warning System CHIME WARNING SYSTEM The chime warning system operates on battery voltage received through a fuse in the Junction Block (JB) on a non switched fused B(+) circuit so that the system may operate regardless of the ignition switch position. The chime warning system also monitors the ignition switch position so that some chime features are functional only with the ignition switch in the ON position, while others are functional regardless of the ignition switch position. The chime warning system provides an audible indication to the vehicle operator or occupants under the following conditions: - Airbag Indicator Warning - The instrument cluster, also known as the Cab Compartment Node (CCN) transducer generates one short chime when the ignition switch is in the ON position, and an electronic message is received over the Controller Area Network (CAN) data bus from the Occupant Restraint Controller (ORC) requesting airbag indicator illumination. This warning only occurs following completion of the airbag indicator bulb test, and only occurs once during any ignition cycle. - Door Ajar Indicator Warning - The CCN transducer generates one short chime when the ignition switch is in the ON position, a hardwired input is received indicating that the status of any door ajar switch has changed, and an electronic message is received over the CAN data bus indicating that the vehicle is moving. - Electronic Stability Program/Brake Assist System Warning - The CCN transducer generates one short chime when the Electronic Stability Program (ESP)/Brake Assist System (BAS) has been manually disabled by the vehicle operator using the ESP/BAS traction control switch on the instrument panel. - Electronic Stability Program/Brake Assist System Fault Warning - The CCN transducer generates one short chime each time the Electronic Stability Program (ESP)/Brake Assist System (BAS) indicator is illuminated in the instrument cluster. This warning indicates a failure condition has been monitored affecting the operation of the ESP/BAS related components or circuits. This warning only occurs following completion of the ESP/BAS indicator bulb test, and only occurs once during any ignition cycle. - Electronic Vehicle Information Center Data Reset - The CCN transducer generates one short chime when the ignition switch is in the ON position, and an electronic message is received over the CAN data bus from the optional Electronic Vehicle Information Center (EVIC) requesting that the EVIC average fuel economy, trip odometer, distance to empty or customer programmable features data be reset. The EVIC monitors hardwired inputs from the EVIC control push button switches to determine the proper reset messages to send to the CCN. Fasten Seat Belt Indicator Warning- The CCN transducer repetitive chimes at a slow rate to announce that a hardwired input from the seatbelt switch indicates that the driver side front seat belt is not fastened with the ignition switch in the ON position. The chime warning system also supports the enhanced seatbelt reminder (beltminder) when this feature is enabled. See: Seat Belt Reminder Lamp/Description and Operation/Seat Belt Warning Lamp - Operation. - Gate Ajar Indicator Warning - The CCN transducer generates one short chime when the ignition switch is in the ON position, a hardwired input is received indicating that the status of the liftgate ajar switch has changed, and an electronic message is received over the CAN data bus indicating that the vehicle is moving. - Head/Park Lamps-On Warning - The CCN transducer will generate repetitive chimes at a fast rate to indicate that hard wired inputs from the driver door ajar switch, the headlamp switch, and the ignition switch indicate that the exterior lamps are turned on with the driver side front door opened and the ignition switch in the OFF position. The chimes continues to sound until the exterior lamps are turned off, the driver side front door is closed, or the ignition switch is turned to the ON position, whichever occurs first. - Key-In-Ignition Warning - The CCN transducer generates repetitive chimes at a fast rate to indicate that hardwired inputs from the driver door ajar switch, the ignition switch, and the key-in ignition switch circuitry of the ignition switch indicate that the key is in the ignition lock cylinder with the driver side front door open and the ignition switch in the OFF position. The chimes continues to sound until the key is removed from the ignition lock cylinder, the driver side front door is closed, or the ignition switch is turned to the ON position, whichever occurs first. - Low Fuel Indicator Warning - The CCN transducer generates one short chime when the low fuel indicator is illuminated by the instrument cluster circuitry. This chime only occurs once during any ignition cycle. - Low Wash Indicator Warning - The CCN transducer generates one short chime when the low washer fluid indicator is illuminated by the instrument cluster circuitry. This chime only occurs once during any ignition cycle. - Overspeed Warning - The CCN transducer generates repetitive chimes at a slow rate to indicate that the vehicle speed is over a pre-programmed speed value. The CCN monitors electronic vehicle speed messages received over the CAN data bus. This feature is only enabled on a CCN that has been programmed with a Middle East Gulf Coast Country (GCC) country code. - Park Brake Reminder - The CCN transducer generates one short chime to announce that the hardwired input from the park brake switch and an electronic vehicle speed message received over the CAN data bus indicate that the park brake is applied and the vehicle is moving. This chime repeats each time the input conditions are met. Sentry Key Customer Learn Mode Announcement - The CCN transducer generates one short chime to confirm that an electronic Customer Learn mode message has been received over the CAN data bus to indicate that the Sentry Key REmote Entry Module (SKREEM) is prepared for programming additional sentry key transponders. This chime feature is only active on vehicles equipped with the optional Sentry Key system, and sold in a market where Customer Learn programming is an allowed feature. - Transmission Overtemp Indicator Warning- The CCN transducer generates repetitive chimes at a slow rate when the transmission overtemp indicator is illuminated by the instrument cluster circuitry for a high or critical transmission fluid temperature condition. This chime repeats each time the trans overtemp indicator is cycled from off to on. - Turn Signal/Hazard Warning Flasher Emulation - The CCN relay generates repetitive clicks at a slow rate to emulate an electromechanical Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Chime/Buzzer - Description > Page 9623 flasher when the turn signal or hazard warning system are operating. The relay generates repetitive clicks at a fast rate to indicate that the right or left turn signal are operating with one or more bulbs ineffective. In either case, the clicks continues until the turn signal and hazard warning systems are turned off. - Turn Signal On Warning - The CCN transducer generates repetitive chimes at a slow rate to indicate that a turn signal has been active continuously for 1.6 kilometers (1 mile) with the vehicle speed greater than 22 kilometers-per-hour (15 miles-per hour). Vehicles built for markets other than the United States and Canada have a revised distance threshold of 4 kilometers (2.49 miles) for this feature. The chime continues until the turn signal input becomes inactive or until the electronic vehicle speed message indicates that the speed is less than 22 kilometers-per-hour (15 miles-per-hour), whichever occurs first. The hazard warning flashers will not activate this chime feature. - Warning Indicator Announcement - The CCN transducer generates one short chime each time the check gauges indicator is illuminated by the instrument cluster circuitry. The check gauges indicator may be illuminated when any critical engine or transmission systems are operating outside of their normal parameters. The instrument cluster monitors electronic messages received over the CAN data bus to determine when to illuminate the check gauges indicator. The CCN provides chime service for all available features in the chime warning system. The CCN relies upon its internal programming, numerous hardwired inputs, and electronic message inputs received from other modules over the CAN data bus network to provide the chime warning system features. The internal programming of the CCN determines the priority of each chime request input that is received, as well as the rate and duration of each chime that is to be generated. The hardwired circuits between components related to the chime warning system may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the chime warning system or the electronic controls or communication between modules and other devices that provide some features of the chime warning system. The most reliable, efficient, and accurate means to diagnose the chime warning system or the electronic controls and communication related to chime warning system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Park Assist System PARK ASSIST SYSTEM The park assist system is active only when the ignition switch is in the ON or START positions, the parking brake is released, the transmission gear selector lever is in either the REVERSE position and the vehicle speed is less than 16 kph (10 mph) or, the DRIVE position and the vehicle speed is less than 14 kph (8 mph) on deceleration, or 18 kph (12 mph) on acceleration. In vehicles equipped with this option, the system is enabled from the factory as a default. The system can be manually disabled and enabled by the vehicle operator using the customer programmable features option of the Electronic Vehicle Information Center (EVIC) in the overhead console. Reasons for disabling the system include trailer towing and off road use. With a trailer attached to the vehicle the audible and visible park assist alerts would be incessant whenever the gear selector lever was in the REVERSE position due to the proximity of the trailer to the rear of the vehicle. Similarly, operating the vehicle off road may cause the park assist alerts to become distracting due to the proximity of large trees or boulders and the extreme rear approach angles that may be encountered while maneuvering on off road trails or terrain. When the system is disabled, a PARK ASSIST DISABLED textual message will appear in the EVIC display whenever the gear selector lever is in the REVERSE position. The microprocessor based park assist module is the central component of the park assist system. It supplies voltage to the park assist sensors and the park assist display, receives and analyzes data from the sensors, calculates and communicates the proper display information to the park assist display, performs system diagnostics, and communicates with other electronic modules in the vehicle or with a diagnostic scan tool over the Controller Area Network (CAN) data bus. The module operates on battery voltage received through a fuse in the Junction Block (JB), and is grounded through a take out and eyelet terminal of the body wire harness that is secured by a screw to the left inner D-pillar. Four ultrasonic park assist sensors in the rear bumper fascia allow the park assist system to locate and identify the proximity of nearby obstacles. These sensors each generate ultrasonic sound pulses when triggered by the park assist module, then signal the module when an echo of the reflected sound pulses is received. The detection distance range from the rear of the vehicle is about 0.3 meters (11.8 inches) to about 2.0 meters (80 inches), and the detection height range from the ground is about 0.2 meters (7.8 inches) to about 0.8 meters (31 inches). The detection area extends somewhat around both rear sides (corners) of the vehicle. The park assist display unit provides the vehicle operator with both visible and audible warnings indicating the relative range of a detected object. The display is visible to the vehicle operator over an inboard shoulder when looking rearward while backing the vehicle up, but is not visible in a properly adjusted inside rear view mirror when looking forward. The display contains two sets of eight Light Emitting Diode (LED) indicator units, one set dedicated to each side of the vehicle, and an audible chime tone transducer. The LED units are concealed beneath a smoked oval lens and are not clearly visible when they are not illuminated. When the park assist system is active and no obstacles are detected (stand-by mode), the two rectangular amber LED units in the display are illuminated at a reduced intensity to provide visual confirmation that the system is operating. The display provides a visual indication of a detected object and its proximity by illuminating one or more LED indicators, beginning with the outer most round amber indicators and moving toward the center of the display as the vehicle gets closer to the object. As the vehicle comes to within about 200 centimeters (about 78.7 inches) of the object, one or both of the inner most rectangular amber LED indicators illuminate at full intensity and the display Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Chime/Buzzer - Description > Page 9624 emits a single half-second audible beep. As the vehicle comes to within about 50 centimeters (19.7 inches) of the object, all of the amber indicators and the first red LED indicator are illuminated and the display emits a series of short, intermittent, audible beeps. If the audio system is turned ON, the audio output will be muted automatically while the park assist audible warning is being generated. The audible warning changes from intermittent beeps to a continuous tone as the final red indicator is illuminated and the vehicle comes to within 30 centimeters (11.8 inches) of a detected object. When the park assist module monitors a problem in any of the park assist system circuits or components, it stores a fault code or Diagnostic Trouble Code (DTC) in its memory circuit, illuminates all four red LED units in the park assist display, sends an electronic message to the EVIC, and a SERVICE PARK ASSIST SYSTEM textual message is displayed in the EVIC display. The hard wired circuits between components related to the park assist system may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the park assist system or the electronic controls or communication between modules and other devices that provide some features of the park assist system. The most reliable, efficient, and accurate means to diagnose the park assist system or the electronic controls and communication related to park assist system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Chime/Buzzer - Chime Warning System Audible Warning Device: Testing and Inspection Chime/Buzzer - Chime Warning System CHIME WARNING SYSTEM WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. The hard wired circuits between components related to the chime warning system may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the chime warning system or the electronic controls or communication between modules and other devices that provide some features of the chime warning system. The most reliable, efficient, and accurate means to diagnose the chime warning system or the electronic controls and communication related to chime warning system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Chime/Buzzer - Chime Warning System > Page 9627 Audible Warning Device: Testing and Inspection Chime/Buzzer - Park Assist System PARK ASSIST SYSTEM WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. If a SERVICE PARK ASSIST SYSTEM textual message appears in the Electronic Vehicle Information Center (EVIC) display, be certain to confirm the following: - Be certain that the rear bumper is free of dirt and debris to keep the system operating properly. - Be certain that the parking brake is not applied. - The presence of jackhammers, large trucks, and other vibrations in the vicinity of the vehicle could impact the performance of the system. The hard wired circuits between components related to the park assist system may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the park assist system or the electronic controls or communication between modules and other devices that provide some features of the park assist system. The most reliable, efficient, and accurate means to diagnose the park assist system or the electronic controls and communication related to park assist system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Brake/Parking Brake Indicator - Description Brake Warning Indicator: Description and Operation Brake/Parking Brake Indicator - Description DESCRIPTION A brake indicator is standard equipment on all instrument clusters. This indicator is located in the center of the speedometer, in the area below and right of the speedometer needle hub. The brake indicator consists of a stencil-like cutout of the word BRAKE (all clusters with a miles-per-hour primary speedometer scale), or the International Control and Display Symbol icon for Brake Failure (all clusters with a kilometers-per-hour primary scale) in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Brake/Parking Brake Indicator - Description > Page 9632 Brake Warning Indicator: Description and Operation Brake/Parking Brake Indicator - Operation OPERATION The brake indicator gives an indication to the vehicle operator when the parking brake is applied, when there are certain brake hydraulic system malfunctions as indicated by a low brake hydraulic fluid level condition, or when the brake fluid level switch is disconnected. The brake indicator can also give an indication when certain faults are detected in the Antilock Brake System (ABS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus, and a hard wired input from the park brake switch. The brake indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the brake indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the brake indicator illuminates for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - Brake Indicator Lamp-On Message - Each time the cluster receives an electronic brake indicator lamp-on message from the CAB, the brake indicator illuminates. The CAB may also send lamp-on messages as feedback during ABS diagnostic procedures. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Park Brake Switch Input - Each time the cluster detects ground on the park brake switch sense circuit (park brake switch closed = park brake applied or not fully released) while the ignition switch is in the ON position, the brake indicator flashes on and off. The indicator continues to flash until the park brake switch sense input to the cluster is an open circuit (park brake switch open = park brake fully released), or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the instrument cluster is put through the self test, the brake indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hardwired ground input to the instrument cluster circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CAB continually monitors the ABS system circuits and sensors, including the brake fluid level switch on the brake master cylinder reservoir, to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction or that the ABS system has become ineffective. The CAB stores a Diagnostic Trouble Code (DTC) for any malfunction it detects. For further diagnosis of the brake indicator or the instrument cluster circuitry that controls the LED, See: Instrument Cluster / Carrier/Testing and Inspection. Use conventional diagnostic tools and procedures for the hardwired park brake switch input to the instrument cluster. Refer to the appropriate wiring information. Use a diagnostic scan tool for proper diagnosis of the brake fluid level switch, the ABS, the CAB, the CCN, the CAN data bus or the electronic communication related to brake indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Brake/Parking Brake Indicator - Description > Page 9633 Brake Warning Indicator: Description and Operation Regenerative Brake Indicator - Description DESCRIPTION A Regenerative Brake System (RBS) indicator is only found in the instrument clusters of vehicles equipped with the optional Hybrid Electrical Vehicle (HEV) system. This indicator is located below the minor gauge set on the left side of the cluster. The RBS indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Failure of Anti-lock Braking System in the opaque layer of the instrument cluster overlay, but with the letter R replacing the letter A in the ABS acronym. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The RBS indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Brake/Parking Brake Indicator - Description > Page 9634 Brake Warning Indicator: Description and Operation Regenerative Brake Indicator - Operation OPERATION The Regenerative Brake System (RBS) indicator gives an indication to the vehicle operator when the RBS system, or a circuit or component of the system is ineffective. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Regenerative Brake Controller (RBC) (also known as the Controller Antilock Brake/CAB) over the Controller Area Network (CAN) data bus. The RBS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the RBS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turns to the on position the RBS indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the RBC. - RBS Indicator Lamp-On Message - Each time the cluster receives an electronic RBS indicator lamp-on message from the RBC, the RBS indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the RBC, or until the ignition switch turns to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the RBC for five consecutive message cycles, the RBS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the RBC, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the instrument cluster is put through the self test, the RBS indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - RBS Diagnostic Test - The RBS indicator is blinked on and off by lamp-on and lamp-off messages from the RBC during the performance of the RBS diagnostic tests. The RBC continually monitors the RBS circuits and sensors to decide whether the system is in good operating condition. The RBC then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the RBC sends a lamp-on message after the bulb test, it indicates that the RBC has detected a system malfunction or that the RBS system has become ineffective. The RBC stores a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the RBS indicator fails to light due to an open or short in the cluster RBS indicator circuit, the cluster sends a message notifying the RBC of the condition, then the instrument cluster and the RBC will each store a DTC. Use a diagnostic scan tool for proper diagnosis of the regenerative brake system, the RBC, the CCN, the CAN data bus or the electronic communication related to RBS indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation > Page 9635 Brake Warning Indicator: Testing and Inspection BRAKE INDICATOR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. The hardwired park brake switch input to the instrument cluster, also known as the Cab Compartment Node, (CCN) may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire harness and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CCN, the Controller Antilock Brake (CAB), the Controller Area Network (CAN) data bus or the electronic message inputs also used by the CCN to provide brake indicator operation. The most reliable, efficient and accurate means to diagnose the CCN, the CAB, the CAN data bus or the electronic communication related to brake indicator operation, requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation > Charging Indicator - Description Charge Lamp/Indicator: Description and Operation Charging Indicator - Description DESCRIPTION A charging indicator is standard equipment on all instrument clusters. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The charging indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Battery Charging Condition in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The charging indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation > Charging Indicator - Description > Page 9640 Charge Lamp/Indicator: Description and Operation Charging Indicator - Operation OPERATION The charging indicator gives an indication to the vehicle operator when the electrical system voltage is too low or too high. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The charging indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the charging indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the on position the charging indicator is illuminated by the instrument cluster for about two seconds as a bulb test. - Voltage Low Message - Each time the cluster receives an electronic system voltage message from the PCM indicating the voltage is low (less than about 11.5 volts is a charge fail condition), the charging indicator illuminates. The indicator remains illuminated until the cluster receives a message from the PCM indicating the voltage is normal (greater than about 12.0 volts, but less than 16.0 volts), or until the ignition switch turns to the off position, whichever occurs first. - Voltage High Message - Each time the cluster receives an electronic system voltage message from the PCM indicating the voltage is high (greater than about 16.0 volts), the charging indicator illuminates. The indicator remains illuminated until the cluster receives a message from the PCM indicating the voltage is normal (less than about 15.5 volts, but greater than 11.5 volts), or until the ignition switch turns to the off position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the charging indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the electrical system voltage to control the generator output. The PCM then sends the proper messages to the instrument cluster, also known as the Cab Compartment Node (CCN). If the instrument cluster turns on the charging indicator due to a charge fail or voltage high condition, it may indicate that the charging system requires service. For further diagnosis of the charging indicator or the instrument cluster circuitry that controls the indicator, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the charging system, the PCM, the CCN, the CAN data bus or the electronic communication related to charging indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9645 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9646 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9647 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9648 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9649 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9650 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9651 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9652 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9653 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9654 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9655 Cigarette Lighter: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9656 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9657 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9658 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9659 Cigarette Lighter: Electrical Diagrams HORN/CIGAR LIGHTER/POWER OUTLET - Diagrams PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9660 Horn/Cigar Lighter/Power Outlet 8W-41-01 Horn/Cigar Lighter/Power Outlet 8W-41-02 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 9661 Horn/Cigar Lighter/Power Outlet 8W-41-03 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Locations > Page 9665 Clock: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY MODULE-CLOCK-ANALOG - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Description and Operation > Clock - Description Clock: Description and Operation Clock - Description DESCRIPTION Some models include an analog clock. Adjust the time by pushing the set button until it reaches the desired time. The analog clock is located in the instrument panel center bezel, above the air distribution outlets. It has one adjustment button for setting and no second hand. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Description and Operation > Clock - Description > Page 9668 Clock: Description and Operation Clock - Operation OPERATION The analog clock is fed power through the M1 fuse. When installed, the clock, along with other non-critical options, will be functional. To set the analog clock, press and hold the adjustment button until the desired time is reached. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Service and Repair > Clock - Removal Clock: Service and Repair Clock - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the Instrument Panel Center Bezel See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Remove the two retaining screws (1) holding the clock to the rear of the instrument panel Center Bezel. 4. To replace the clock illumination lamps, turn the sockets (1) counterclockwise to remove the lamp and socket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Service and Repair > Clock - Removal > Page 9671 Clock: Service and Repair Clock - Installation INSTALLATION 1. Place the lamp and sockets (1) into the opening and turn clockwise until detent is felt. 2. Place the clock into bezel opening and install the two retaining screws (1). 3. Install the instrument panel center bezel See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Installation. 4. Connect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Service and Repair > Clock - Removal > Page 9672 5. Adjust the clock to the proper time. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Manual Compass Calibration Compass: Adjustments Manual Compass Calibration MANUAL COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the overhead console. Do not use magnetic tools when servicing the overhead console. NOTE: Whenever the compass is calibrated manually, the variance number must also be reset. See: Driver/Vehicle Information Display/Adjustments for the appropriate procedure. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or the Electronic Vehicle Information Center (EVIC) displays "CAL", perform the following manual calibration procedure. Also, any time EVIC service replacement components are installed, they must be calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. Calibrate the compass manually as follows: 1. Turn the ignition switch to the On/Run position. Press and release the MENU push button (1) until "Personal Settings" is displayed. 2. Press the STEP push button (2) until "Calibrate Compass YES" is displayed. 3. Momentarily depress and release the RESET push button (4) to initiate the calibration procedure. The message "CAL will appear in the Compass /Temperature display. 4. Slowly drive the vehicle on a level surface, away from large metal objects and power lines, through one or two complete circles not exceeding 8 km/h (5 mph). The "CAL" message will disappear from the display to indicate that the compass is now calibrated. NOTE: A blank compass display indicates that vehicle degaussing (demagnetizing) may be necessary. NOTE: If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the EVIC is inoperative. Attempt the calibration procedure at least one more time before performing EVIC diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the manual calibration procedure in another location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Manual Compass Calibration > Page 9677 Compass: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Variance Settings Map Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. NOTE: If the vehicle is taken on long trips into a new variance zone the compass function may be effected. Compass variance may need to be adjusted to the new zone number to function properly. NOTE: The default for the compass variance from the factory is 8. To set the compass variance: 1. Using the Variance Settings Map, find your geographic location and note the zone number. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Manual Compass Calibration > Page 9678 2. Turn the ignition switch to the On/Run position. Press and release the MENU push button (1) until "Personal Settings" is displayed. 3. Press the STEP push button (2) until "Compass Variance" is displayed. 4. Momentarily depress and release the RESET push button (4) to toggle through the zone numbers (1-15), until the zone number for your geographic location appears in the display. 5. Momentarily depress and release the C/T push button (5) to enter the displayed zone number into the compass unit memory. 6. Confirm that the correct directions are now indicated by the compass. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Adjustments > Page 9679 Compass: Service and Repair COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 3. Slowly approach the head of the overhead console forward mounting screw with the degaussing tool connected. 4. Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. 5. With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is at least 61 centimeters (2 feet) from the screw head, disconnect the tool. To demagnetize the roof panel proceed as follows: 6. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 7. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 8. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 9. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 10. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 11. Calibrate the compass and adjust the compass variance, See: Adjustments/Compass Variance Adjustment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Description and Operation > Cruise Control Indicator - Description Cruise Control Indicator Lamp: Description and Operation Cruise Control Indicator - Description DESCRIPTION A cruise indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional speed control system, this indicator is electronically disabled. The cruise indicator is located below the minor gauge set on the left side of the cluster. The cruise indicator consists of a stencil-like cutout of the word CRUISE in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A green Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in green through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON the illumination intensity of the cruise indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The cruise indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp > Component Information > Description and Operation > Cruise Control Indicator - Description > Page 9684 Cruise Control Indicator Lamp: Description and Operation Cruise Control Indicator - Operation OPERATION The cruise indicator indicates to the driver when the speed control system is on, regardless of whether or not the speed control is engaged. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The cruise indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit, and that logic only allows this indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns the cruise indicator on for the following reasons: - Cruise Indicator Lamp-On Message - Each time the cluster receives an electronic cruise indicator lamp-on message from the PCM indicating the speed control system is on, the cruise indicator is illuminated. The indicator remains illuminated until the cluster receives a lamp-off message from the PCM or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the cruise indicator is turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the speed control switches to determine the appropriate outputs to control the vehicle speed. The PCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the cruise indicator or the instrument cluster circuitry that controls the LED, See: Instrument Cluster / Carrier/Testing and Inspection. A diagnostic scan tool is required for proper diagnosis of the speed control system, the PCM, the CCN, the CAN data bus or the electronic communication related to cruise indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation > Door Ajar Warning Indicator - Description Door/Trunk Ajar Indicator/Lamp: Description and Operation Door Ajar Warning Indicator Description DESCRIPTION A door ajar indicator is standard equipment on all instrument clusters. This indicator is located within the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. The door ajar indicator consists of the text DOOR, which appears in place of the odometer/trip odometer information in the odometer VFD unit. However, on vehicles equipped with the optional Electronic Vehicle Information Center (EVIC), an additional International Standards Organization (ISO) symbol for an open door is also provided by the EVIC. The odometer VFD is soldered onto the cluster electronic circuit board, and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The door ajar indicator appears in the same blue-green color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The door ajar indicator is serviced as a unit with the VFD in the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation > Door Ajar Warning Indicator - Description > Page 9689 Door/Trunk Ajar Indicator/Lamp: Description and Operation Door Ajar Warning Indicator Operation OPERATION The door ajar indicator gives an indication to the vehicle operator that one or more of the passenger compartment doors may be open or not completely latched. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and hardwired inputs received by the cluster from the door ajar switches located in each door latch unit. The door ajar indicator function of the Vacuum Fluorescent Display (VFD) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the VFD door ajar indication is always off when the ignition switch is in any position except ON or START. The instrument cluster turns on the door ajar indicator for the following reasons: - Door Ajar switch input - Each time the cluster detects ground on any one of the door ajar switch sense circuits (door ajar switch closed = door is open or not completely latched) the door ajar indicator illuminates. The indicator remains illuminated until all of the door ajar switch sense inputs to the cluster are an open circuit (door ajar switch open = door fully closed), until the cluster has completed an interior lamps load shed (about five minutes), or until the ignition switch turns to the OFF position, whichever occurs first. The instrument cluster, also known as the Cab Compartment Node (CCN) continually monitors the door ajar switches to determine the status of the doors. For further diagnosis of the door ajar indicator or the instrument cluster circuitry that controls the indicator, See: Instrument Cluster / Carrier/Testing and Inspection. Use conventional diagnostic tools and procedures for the hardwired door ajar switches and circuits related to door ajar indicator operation. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Description and Operation > Door Ajar Switch - Description Door Switch: Description and Operation Door Ajar Switch - Description DOOR This vehicle has four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Latch/Service and Repair/Front Door Latch - Removal or See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Rear Door Latch - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Description and Operation > Door Ajar Switch - Description > Page 9694 Door Switch: Description and Operation Door Ajar Switch - Operation DOOR The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The rear door ajar switches are hard wired in series between a body ground and the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). On vehicles not equipped with the optional memory system, the front door ajar switches are also hard wired in series between ground and the EMIC. On vehicles equipped with the optional memory system each front door ajar switch is hard wired in series between ground and its respective driver or passenger Memory Mirror Module (MMM) located in the front door. The MMM then sends electronic door ajar switch status messages to the EMIC over the Controller Area Network (CAN) data bus. Both the EMIC and the MMM read the hard wired door ajar switch inputs through internal pull-ups, then use these inputs to control many electronic functions and features of the vehicle. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup Driver/Vehicle Information Display: Technical Service Bulletins Instruments - Vehicle Information Center Setup NUMBER: 08-002-09 GROUP: Electrical DATE: February 4, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-014-07, DATED JULY 11, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL YEARS AND MODELS. SUBJECT: Electronic Vehicle Information Center (EVIC) Oil Change Indicator System - Dealer Preferences During Prep MODELS: 2008 (DR) Ram Truck **2009 (HB) Durango** **2009 (HG) Aspen** **2009 (JC) Journey** **2008 - 2009 (KA) Nitro** **2008 - 2009 (KK) Liberty** **2009 (LC) Challenger** **2008 - 2009 (LX) 300 / Magnum / Charger** **2008 - 2009 (RI) Caravan / Town & Country** NOTE: This Bulletin applies to vehicles equipped with a programmable EVIC. DISCUSSION: **Many models now include an oil change indicator system**. This system displays an "Oil Change Required" or "Oil Change" message at appropriate intervals on the instrument cluster. The vehicles listed above may be equipped with a programmable display on the Electronic Vehicle Information Center, (EVIC). The "Oil Change Required message may also include the dealerships name and phone number which can be programmed into the vehicle with the StarSCAN(R) or StarMOBILE(R) scan tool. NOTE: **Other vehicles may be added at any time. Dealers can determine if the feature is available by following the procedures below. If Enable/Disable Dealer Contact Information is active, the feature can be used to enter the servicing dealer's information.** The following procedure describes the steps to add, delete or change a dealership name and phone number on the display. NOTE: If NOT programmed during vehicle prep, customer approval MUST be obtained before adding or changing this information. NOTE: When performing this Procedure, the software release level in the StarSCAN(R) or StarMOBILE(R); must be programmed with the latest level software. The software release level is visible in the blue header at the top of the StarSCAN(R) or StarMOBILE(R) screen. 1. Connect the StarSCAN(R) or StarMOBILE(R). (in Pass-Through Mode) NOTE: To use the StarMOBILE(R) in Pass-Through Mode requires that StarMOBILE(R) be connected to the dealership network via a wired or wireless connection. For more information on how to use the StarMOBILE(R) in Pass-Through Mode, see the StarMOBILE(R) training tutorials available on DealerCONNECT > Service > Repair > StarSCAN(R) and StarMOBILE(R) Tools link or at the website. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup > Page 9699 2. From the Home Screen, enter "ECU VIEW or "VEHICLE PREP". 3. Select "CCN". 4. Select "Misc. Functions". 5. Select "Enable/Disable Dealer Contact Information". 6. Select "Enable" or "Disable" as desired. 7. If enabled, select "Program Dealer Contact Information" and follow on screen prompts. 8. "Reset will cause display to read: "Contact Dealer" as default. 9. Select finish to exit. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 9700 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions Driver/Vehicle Information Display: Diagram Information and Instructions Warnings WARNINGS - GENERAL WARNINGSprovide information to prevent personal injury and vehicle damage. Below is a list of general warnings that should be followed any time a vehicle is being serviced. WARNING: Always wear safety glasses for eye protection. WARNING: Use safety stands anytime a procedure requires being under a vehicle. WARNING: Be sure that the ignition switch always is in the off position, unless the procedure requires it to be on. WARNING: Set the parking brake when working on any vehicle. An automatic transmission should be in park. A manual transmission should be in neutral. WARNING: Operate the engine only in a well-ventilated area. WARNING: Keep away from moving parts when the engine is running, especially the fan and belts. WARNING: To prevent serious burns, avoid contact with hot parts such as the radiator, exhaust manifold(s), tail pipe, catalytic converter and muffler. WARNING: Do not allow flame or sparks near the battery. Gases are always present in and around the battery. WARNING: Always remove rings, watches, loose hanging jewelry and avoid loose clothing. Warnings Hybrid Electric Vehicles (HEV) WARNINGS - HYBRID ELECTRIC VEHICLES (HEV) Hybrid Electric Vehiclesare equipped with a high voltage components and wiring. Each high voltage component is labeled with the high voltage symbol. High voltage cables are orange in color or protected by metal conduit. WARNING: On vehicles equipped with the high voltage system, you must thoroughly read and follow all High Voltage Safety Procedures. These procedures are located in the Service tab, section 08-Electrical. In addition, before performing any diagnostic or service procedure near a high voltage component, you must perform the High Voltage Power Down procedure located in the Service Tab, 08-Electrical/8 - Engine Systems/Battery System - Standard Procedure. Failure to follow these instructions may result in possible serious or fatal injury. How to Use Wiring Diagrams Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9703 HOW TO USE WIRING DIAGRAMS Chrysler Corporation wiring diagrams are designed to provide information regarding the vehicles wiring content. In order to effectively use the wiring diagrams to diagnose and repair Chrysler Corporation vehicles, it is important to understand all of their features and characteristics. Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the page, and the ground (B-) side of the circuit is placed near the bottom of the page. All switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. Components are shown two ways. A solid line around a component indicates that the component is complete. A dashed line around the component indicates that the component is being shown is not complete. Incomplete components have a reference number to indicate the page where the component is shown complete. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9704 SYMBOLS International symbols are used throughout the wiring diagrams. These symbols are consistent with those being used around the world. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9705 TERMINOLOGY This is a list of terms and definitions used in the wiring diagrams. LHD - Left Hand Drive Vehicles RHD - Right Hand Drive Vehicles ATX - Automatic Transmissions-Front Wheel Drive MTX Manual Transmissions-Front Wheel Drive AT - Automatic Transmissions-Rear Wheel Drive MT Manual Transmissions-Rear Wheel Drive SOHC - Single Over Head Cam Engine DOHC - Double Over Head Cam Engine Export - Vehicles Built For Sale In Markets Other Than North America Except Export - Vehicles Built For Sale In North America Circuit Functions CIRCUIT FUNCTIONS All circuits in the diagrams use an alpha/numeric code to identify the wire and it's function. To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9706 CIRCUIT IDENTIFICATION CODE CHART Circuit Information CIRCUIT INFORMATION Each wire shown in the diagrams contains a code which identifies the main circuit, a specific part of the main circuit, gage of wire, and color. An example would be A 2 18 LB/YL. This is a Battery Feed circuit, level two, eighteen gauge, light blue with a yellow tracer. WIRE COLOR CODE CHART Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9707 Connector, Ground and Splice Information CONNECTOR, GROUND AND SPLICE INFORMATION CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A typical example might be the Supplemental Restraint System connectors. Always check parts availability before attempting a repair. IDENTIFICATION In-line connectors are identified by a number, as follows: - In-line connectors located in the engine compartment are C100 series numbers. - In-line connectors located in the instrument panel area are C200 series numbers. - In-line connectors located in the body are C300 series numbers. - Jumper harness connectors are C400 series numbers. - Grounds and ground connectors are identified with a "G" and follow the same series numbering as the in-line connectors. - Splices are identified with an "S" and follow the same series numbering as the in-line connectors. In addition, S001-S099 numbers are located in the engine compartment. - Component connectors are identified by the component name instead of a number. Multiple connectors on a component use a C1, C2, etc. identifier. LOCATIONS Section 8W-91 contains connector/ground/splice location illustrations. The illustrations contain the connector name (or number)/ground number/splice number and component identification. Connector/ground/splice location charts in section 8W-91 reference the figure numbers of the illustrations. The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component. The abbreviation N/S means Not Shown in the illustrations Section Identification and Information Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9708 SECTION IDENTIFICATION AND INFORMATION The wiring diagrams are grouped into individual sections. If a component is most likely found in a particular group, it will be shown complete (all wires, connectors, and pins) within that group. For example, the Auto Shutdown Relay is most likely to be found in Group 30, so it is shown there complete. It can, however, be shown partially in another group if it contains some associated wiring. Splice diagrams in Section 8W-70 show the entire splice and provide references to other sections the splices serves. Section 8W-70 only contains splice diagrams that are not shown in their entirety somewhere else in the wiring diagrams. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the name/number on the diagram pages. Removal REMOVAL 1. Disconnect battery. 2. Release Connector Lock (2). 3. Disconnect the connector (3) being repaired from its mating half/component. 4. Remove the dress cover (if applicable) (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9709 5. Release the Secondary Terminal Lock, if required (1). 6. Position the connector locking finger away from the terminal using the proper special tool. Pull on the wire to remove the terminal from the connector. Installation INSTALLATION 1. Insert the removed terminal in the same cavity on the repair connector. 2. Repeat steps for each terminal in the connector, being sure that all wires are inserted into the proper cavities. For additional connector pin-out identification, refer to the wiring diagrams. 3. When the connector is re-assembled, the secondary terminal lock must be placed in the locked position to prevent terminal push out. 4. Replace dress cover (if applicable). 5. Connect connector to its mating half/component. 6. Connect battery and test all affected systems. Removal REMOVAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9710 1. Disconnect the battery. 2. Locate the diode in the harness, and remove the protective covering. 3. Remove the diode from the harness, pay attention to the current flow direction (1) (2) (3). Installation INSTALLATION 1. Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. 2. Install the new diode in the harness, making sure current flow is correct. If necessary, refer to the appropriate wiring diagram for current flow. 3. Solder the connection together using rosin core type solder only. Do not use acid core solder. 4. Tape the diode to the harness using electrical tape. Make sure the diode is completely sealed from the elements. 5. Re-connect the battery and test affected systems. Removal REMOVAL 1. Follow steps for removing terminals described in the connector removal section. 2. Cut the wire 6 inches from the back of the connector. Installation INSTALLATION 1. Select a wire from the terminal repair kit that best matches the color and gage of the wire being repaired. 2. Cut the repair wire to the proper length and remove one-half (1/2) inch of insulation. 3. Splice the repair wire to the wire harness (see wire splicing procedure). 4. Insert the repaired wire into the connector. 5. Install the connector locking wedge, if required, and reconnect the connector to its mating half/component. 6. Re-tape the wire harness starting at 1-1/2 inches behind the connector and 2 inches past the repair. 7. Connect battery and test all affected systems. Wire Splicing WIRE SPLICING When splicing a wire, it is important that the correct gage be used as shown in the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9711 1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced. 2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. 3. Place the strands of wire overlapping each other inside of the splice clip (1). 4. Using crimping tool (1), Mopar p/n 05019912AA, crimp the splice clip and wires together. 5. Solder (3) the connection (2) together using rosin core type solder (1) only. CAUTION: DO NOT USE ACID CORE SOLDER. 6. Center the heat shrink tubing (2) over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant (1) comes out of both ends of the tubing. Special Tools WIRING/TERMINAL Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9712 PROBING TOOL PACKAGE 6807 TERMINAL PICK TOOL SET 6680 TERMINAL REMOVING TOOLS 6932 AND 8638 TERMINAL REMOVING TOOL 6934 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9713 Driver/Vehicle Information Display: Diagnostic Aids Electrostatic Discharge (ESD) Sensitive Devices ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol is used to indicate this. When handling any component with this symbol, comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inadvertent discharge into the component. If it is not known whether the part is ESD sensitive, assume that it is. 1. Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. 2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure. 3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from it's protective packing until it is time to install the part. 5. Before removing the part from it's package, ground the package to a known good ground on the vehicle. Testing Of Voltage Potential TESTING OF VOLTAGE POTENTIAL 1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure. Testing For Continuity TESTING FOR CONTINUITY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9714 1. Remove the fuse (1) for the circuit being checked or, disconnect the battery. 2. Connect one lead of the ohmmeter to one side of the circuit being tested 3. Connect the other lead to the other end of the circuit being tested. Low or no resistance means good continuity. Testing For A Short To Ground TESTING FOR A SHORT TO GROUND 1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. 4. If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. Testing For A Short To Ground On Fuses Powering Several Loads TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS 1. Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. 2. Replace the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. 4. Start connecting or energizing the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated. Testing For A Voltage Drop TESTING FOR A VOLTAGE DROP 1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2. Connect the other lead of the voltmeter to the other side of the switch, component or circuit. 3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points. Troubleshooting Wiring Problems WIRING HARNESS TROUBLESHOOTING TOOLS When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. - Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: Never use a jumper wire across a load, such as a motor, connected between a battery feed and ground. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9715 - Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking voltages in these circuits, use a meter with a 10 - megohm or greater impedance rating. - Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: Most of the electrical components used in today's vehicles are Solid State. When checking resistance in these circuits use a meter with a 10 - megohm or greater impedance rating. In addition, make sure the power is disconnected from the circuit. Circuits that are powered up by the vehicle's electrical system can cause damage to the equipment and provide false readings. - Probing Tools - These tools are used for probing terminals in connectors. Select the proper size tool from Special Tool Package 6807, and insert the probing end (2) into the terminal being tested. Use the other end of the tool (1) to insert the meter probe. INTERMITTENT AND POOR CONNECTIONS Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking component or relay to cause a problem. Before condemning a component or wiring assembly, check the following items. - Connectors are fully seated - Spread terminals, or terminal push out - Terminals in the wiring assembly are fully seated into the connector/component and locked into position - Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent problem - Damaged connector/component casing exposing the item to dirt or moisture - Wire insulation that has rubbed through causing a short to ground - Some or all of the wiring strands broken inside of the insulation - Wiring broken inside of the insulation TROUBLESHOOTING WIRING PROBLEMS When troubleshooting wiring problems there are six steps which can aid in the procedure. The steps are listed and explained below. Always check for non-factory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9716 1. Verify the problem. 2. Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. 3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. 4. Isolate the problem area. 5. Repair the problem area. 6. Verify the proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9717 Driver/Vehicle Information Display: Connector Views Connector - (HEADLINER) 6 WAY MODULE-ELECTRONIC OVERHEAD - (HEADLINER) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9718 Driver/Vehicle Information Display: Electrical Diagrams OVERHEAD CONSOLE - Diagram 02 (HANDS FREE) PLEASE NOTE: Some diagrams may appear to be missing because of gaps in the number sequences. These "gaps" are actually for diagrams that do not apply to the vehicle model selected. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9719 Overhead Console 8W-49-01 Overhead Console 8W-49-02 (Hands Free) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9720 Overhead Console 8W-49-03 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9721 Overhead Console 8W-49-04 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Diagrams > Diagram Information and Instructions > Page 9722 Overhead Console 8W-49-05 Other Diagrams: Other diagrams referred to by number (i.e. 8W-70-2, etc.) within these diagrams can be found at the vehicle level under Diagrams by Number See: Diagrams/Electrical Diagrams/Diagrams By Number Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description Driver/Vehicle Information Display: Description and Operation Liftgate Ajar Indicator - Description DESCRIPTION A gate ajar indicator is standard equipment on all instrument clusters. This indicator is located within the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. The gate ajar indicator consists of the text GATE, which appears in place of the odometer/trip odometer information in the odometer VFD unit. However, on vehicles equipped with the optional Electronic Vehicle Information Center (EVIC), an additional International Standards Organization (ISO) symbol for open liftgate is also provided by the EVIC. The odometer VFD is soldered onto the cluster electronic circuit board, and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The gate ajar indicator appears in the same blue-green color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The gate ajar indicator is serviced as a unit with the VFD unit in the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 9725 Driver/Vehicle Information Display: Description and Operation Liftgate Ajar Indicator - Operation OPERATION The gate ajar indicator gives an indication to the vehicle operator that the rear liftgate may be open or not completely latched. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and a hardwired input received by the cluster from the liftgate ajar switch integral to the liftgate latch unit. The gate ajar indicator function of the Vacuum Fluorescent Display (VFD) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the VFD gate ajar indication is always off when the ignition switch is in any position except ON or START. The instrument cluster turns on the gate ajar indicator for the following reasons: - Liftgate Ajar Switch Input - Each time the cluster detects ground on the liftgate ajar switch sense circuit (liftgate ajar switch closed = gate is open or not completely latched) the gate ajar indicator illuminates. The indicator remains illuminated until the liftgate ajar switch sense input to the cluster is an open circuit (liftgate ajar switch open = liftgate fully closed), until the cluster has completed an interior lamps load shed (about five minutes), or until the ignition switch turns to the off position, whichever occurs first. The instrument cluster, also known as the Cab Compartment Node (CCN) continually monitors the liftgate ajar switch to determine the status of the liftgate. For further diagnosis of the liftgate ajar indicator or the instrument cluster circuitry that controls the indicator, See: Instrument Cluster / Carrier/Testing and Inspection. Use conventional diagnostic tools and procedures for the hardwired liftgate ajar switch and circuits related to gate ajar indicator operation. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 9726 Driver/Vehicle Information Display: Description and Operation No Bus Indicator - Description DESCRIPTION A no-bus indicator is standard equipment on all instrument clusters. The no-bus indication appears within the fixed segment odometer Vacuum Fluorescent Display (VFD) unit. The odometer no-bus indicator consists of a textual No-BUS message that appears in place of the odometer/trip odometer information. The odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located at the base of the cluster overlay right gauge dial face, (Dodge) or the tachometer dial face (Chrysler). The dark lens over the VFD prevents it from being clearly visible when not illuminated. The no-bus textual message appears in the same blue-green color and at the same lighting level as the other information displayed in the odometer VFD unit when illuminated by the instrument cluster electronic circuit board. During daylight hours, (exterior lamps are off) the odometer VFD unit illuminates at full brightness for clear visibility. At night (exterior lamps are on), the VFD lighting level adjusts with the other cluster illumination lamps using the panel lamps dimmer thumbwheel of the headlamp switch on the instrument panel. However, a Parade mode position of the thumbwheel allows the VFD unit to illuminate at full brightness if the exterior lamps are turned on during daylight hours. The no-bus indicator is serviced as a unit with the odometer VFD unit in the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 9727 Driver/Vehicle Information Display: Description and Operation No Bus Indicator - Operation OPERATION The no-bus indicator gives an indication to the vehicle operator when the electronic communication data bus is ineffective. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and electronic messages not being received over the Controller Area Network (CAN) data bus from the Front Control Module (FCM). The no-bus indicator function of the odometer Vacuum Fluorescent Display (VFD) unit is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the odometer VFD no-bus indicator is always off when the ignition switch is in any position except ON or START. The instrument cluster turns ON the no bus indicator for the following reasons: - No Electronic Communication Messages - Each time the ignition switch is turned to the ON position and the cluster does not receive electronic communication messages over the CAN data bus, the no-bus indicator illuminates. The indicator remains illuminated until CAN bus communication is restored or until the ignition switch turns to the OFF position, whichever occurs first. The instrument cluster, also known as the Cab Compartment Node (CCN) continually monitors the CAN data bus to determine the status of many sensors and systems throughout the vehicle. If bus communication is interrupted, the CCN cannot provide accurate displays and outputs. Use a diagnostic scan tool is required for proper diagnosis of the no-bus indicator, the CCN, the CAN data bus or the electronic communication related to no-bus indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 9728 Driver/Vehicle Information Display: Description and Operation Liftgate Ajar Indicator - Description DESCRIPTION A gate ajar indicator is standard equipment on all instrument clusters. This indicator is located within the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. The gate ajar indicator consists of the text GATE, which appears in place of the odometer/trip odometer information in the odometer VFD unit. However, on vehicles equipped with the optional Electronic Vehicle Information Center (EVIC), an additional International Standards Organization (ISO) symbol for open liftgate is also provided by the EVIC. The odometer VFD is soldered onto the cluster electronic circuit board, and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The gate ajar indicator appears in the same blue-green color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The gate ajar indicator is serviced as a unit with the VFD unit in the instrument cluster. Liftgate Ajar Indicator - Operation OPERATION The gate ajar indicator gives an indication to the vehicle operator that the rear liftgate may be open or not completely latched. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and a hardwired input received by the cluster from the liftgate ajar switch integral to the liftgate latch unit. The gate ajar indicator function of the Vacuum Fluorescent Display (VFD) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the VFD gate ajar indication is always off when the ignition switch is in any position except ON or START. The instrument cluster turns on the gate ajar indicator for the following reasons: Liftgate Ajar Switch Input - Each time the cluster detects ground on the liftgate ajar switch sense circuit (liftgate ajar switch closed = gate is open or not completely latched) the gate ajar indicator illuminates. The indicator remains illuminated until the liftgate ajar switch sense input to the cluster is an open circuit (liftgate ajar switch open = liftgate fully closed), until the cluster has completed an interior lamps load shed (about five minutes), or until the ignition switch turns to the off position, whichever occurs first. The instrument cluster, also known as the Cab Compartment Node (CCN) continually monitors the liftgate ajar switch to determine the status of the liftgate. For further diagnosis of the liftgate ajar indicator or the instrument cluster circuitry that controls the indicator, See: Instrument Cluster / Carrier/Testing and Inspection. Use conventional diagnostic tools and procedures for the hardwired liftgate ajar switch and circuits related to gate ajar indicator operation. Refer to the appropriate wiring information. No Bus Indicator - Description DESCRIPTION A no-bus indicator is standard equipment on all instrument clusters. The no-bus indication appears within the fixed segment odometer Vacuum Fluorescent Display (VFD) unit. The odometer no-bus indicator consists of a textual No-BUS message that appears in place of the odometer/trip odometer information. The odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located at the base of the cluster overlay right gauge dial face, (Dodge) or the tachometer dial face (Chrysler). The dark lens over the VFD prevents it from being clearly visible when not illuminated. The no-bus textual message appears in the same blue-green color and at the same lighting level as the other information displayed in the odometer VFD unit when illuminated by the instrument cluster electronic circuit board. During daylight hours, (exterior lamps are off) the odometer VFD unit illuminates at full brightness for clear visibility. At night (exterior lamps are on), the VFD lighting level adjusts with the other cluster illumination lamps using the panel lamps dimmer thumbwheel of the headlamp switch on the instrument panel. However, a Parade mode position of the thumbwheel allows the VFD unit to illuminate at full brightness if the exterior lamps are turned on during daylight hours. The no-bus indicator is serviced as a unit with the odometer VFD unit in the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 9729 No Bus Indicator - Operation OPERATION The no-bus indicator gives an indication to the vehicle operator when the electronic communication data bus is ineffective. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and electronic messages not being received over the Controller Area Network (CAN) data bus from the Front Control Module (FCM). The no-bus indicator function of the odometer Vacuum Fluorescent Display (VFD) unit is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the odometer VFD no-bus indicator is always off when the ignition switch is in any position except ON or START. The instrument cluster turns ON the no bus indicator for the following reasons: - No Electronic Communication Messages - Each time the ignition switch is turned to the ON position and the cluster does not receive electronic communication messages over the CAN data bus, the no-bus indicator illuminates. The indicator remains illuminated until CAN bus communication is restored or until the ignition switch turns to the OFF position, whichever occurs first. The instrument cluster, also known as the Cab Compartment Node (CCN) continually monitors the CAN data bus to determine the status of many sensors and systems throughout the vehicle. If bus communication is interrupted, the CCN cannot provide accurate displays and outputs. Use a diagnostic scan tool is required for proper diagnosis of the no-bus indicator, the CCN, the CAN data bus or the electronic communication related to no-bus indicator operation. Refer to the appropriate diagnostic information. No Fuse Indicator - Description DESCRIPTION A no fuse indicator is standard equipment on all instrument clusters. The no fuse indication appears within the odometer Vacuum Fluorescent Display (VFD) unit. The no fuse indicator consists of a textual noFUSE message which appears in place of the odometer information in the odometer display. The odometer VFD is soldered onto the cluster electronic circuit board, and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The no fuse textual message appears in the same blue-green color and at the same lighting level as the odometer information when it is illuminated by the instrument cluster electronic circuit board. The no fuse indicator is serviced as a unit with the VFD in the instrument cluster. No Fuse Indicator - Operation OPERATION The no-fuse indicator gives an indication to the vehicle operator when the Ignition Off Draw (IOD) fuse is ineffective or is not installed. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Front Control Module (FCM). The no-fuse indicator function of the odometer Vacuum Fluorescent Display (VFD) unit is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the odometer VFD no-fuse indication is always off when the ignition switch is in any position except ON or START. The instrument cluster turns on the no-fuse indicator for the following reasons: - No-Fuse indicator lamp-on message - Each time the ignition switch is turned to the ON position and the cluster receives an electronic no-fuse indicator lamp-on message from the FCM indicating that the IOD fuse is missing or ineffective, the no-fuse indicator illuminates. The indicator remains illuminated for about three seconds, until the IOD fuse installs, until the trip odometer reset switch button pressed or until the ignition switch is turned to the OFF position, whichever occurs first. The FCM continually monitors the IOD circuit to determine the status of the IOD fuse, then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN) over the CAN data bus. Use a diagnostic scan tool is required for proper diagnosis of the no-fuse indicator, the FCM, the CCN, the CAN data bus or the electronic communication related to no-fuse indicator operation. Refer to the appropriate diagnostic information. Service 4WD Indicator - Description Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 9730 DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located below the minor gauge set on the left side of the cluster. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Service 4WD Indicator - Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Front Control Module (FCM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the FCM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-on message from the FCM, the service 4WD indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-off messages from the FCM for 10 seconds, the service 4WD indicator is illuminated by the cluster to indicate a loss of FCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the FCM. - Self Test - Each time the cluster is put through the self test, the service 4WD indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The FCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the FCM, the CCN, the CAN data bus or the electronic communication related to service 4WD indicator operation. Refer to the appropriate diagnostic information. Transmission Temperature Indicator - Description DESCRIPTION A transmission over-temperature indicator is standard equipment on all instrument clusters. This indicator is located in the center of the speedometer, in the area above and to the right of the speedometer needle hub. The transmission over-temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Transmission Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 9731 The transmission over-temperature indicator is serviced as a unit with the instrument cluster. Transmission Temperature Indicator - Operation OPERATION The transmission over-temperature indicator gives an indication to the vehicle operator when the transmission fluid temperature is excessive, which may lead to accelerated transmission component wear or failure. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The transmission over-temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the transmission over-temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the transmission over temperature indicator is illuminated for about two seconds as a bulb test. - Trans Over-Temp Indicator Lamp-On Message - Each time the cluster receives an electronic transmission over temp indicator lamp-on message from the PCM indicating that the transmission fluid temperature is 135 °C (275 °F) or higher, the indicator illuminates and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a lamp-off message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature only repeats during the same ignition cycle if the indicator is cycled off and then on again by the appropriate lamp-on and lamp-off messages from the PCM. - Self Test - Each time the cluster is put through the self test, the transmission over temperature indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the transmission temperature sensor to determine the transmission operating condition. The PCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the instrument cluster illuminates the transmission over temperature indicator due to a high transmission oil temperature condition, it may indicate that the transmission or the transmission cooling system are being overloaded, or that they require service. For further diagnosis of the transmission over-temperature indicator or the instrument cluster circuitry that controls the LED, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transmission temperature sensor, the PCM, the CCN, the CAN data bus or the electronic communication related to transmission over-temperature indicator operation. Refer to the appropriate diagnostic information. Electronic Vehicle Information Center - Description DESCRIPTION NOTE: The Electronic Vehicle Information Center (EVIC) module is sometimes referred to as Electronic Overhead Module (EOM) for the purposes of scan tool and diagnostic information naming. Please treat the EVIC and EOM as one and the same when diagnosing the vehicle. The Electronic Vehicle Information Center (EVIC) is located in the overhead console and consists of the following components: - HomeLink(R) transceiver (3) - if equipped - Vacuum-Fluorescent Display (VFD) (6) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 9732 - Push button function switches (1, 2, 3, 4 and 5) - Replaceable light bulbs to illuminate the push button function switches This system conveniently allows the driver to select a variety of useful information by pressing the function buttons. The EVIC displays information related to the following: - System status - Vehicle information warning message displays - Tire Pressure Monitor System (TPM) - If Equipped - Personal settings (customer programmable features) - Compass display - Outside temperature display - Trip computer functions The EVIC system is comprised of several different components. Those components are: - Instrument Cluster also known as Cab Compartment Node (CCN). - Ambient Temperature Sensor - EVIC Module - Controller Area Network (CAN) Data Bus circuit The only serviceable components of the EVIC module are the push button illumination bulbs, See: Service and Repair/Removal and Replacement/Electronic Vehicle Information Center - Removal. All other components of the EVIC module are not serviced separately and if damaged or inoperative, must be replaced as a unit. Electronic Vehicle Information Center - Operation OPERATION The Electronic Vehicle Information Center (EVIC) uses both non-switched and ignition switched sources of battery current so that some of its features remain operational at any time, while others may only operate with the ignition switch in the On position. When the ignition switch is turned to the On position, the EVIC display will return to the last function being displayed before the ignition was turned to the Off position. The EVIC system is comprised of several different components that communicate over the Controller Area Network (CAN) Data Bus. If the system is inoperative a scan tool and the appropriate diagnostic information must be used to diagnose the system. The EVIC push buttons are used to operate the different functions of the EVIC system. Pressing and releasing the MENU button (1) will change the mode displayed to one of the Personal Settings. The STEP button (2) is used to make a selection from the Personal Settings displayed at that time. Pressing and releasing the C/T (compass/temperature) button (5) will cause the EVIC to return to the compass/temperature/trip computer display mode from any other mode. From the compass/temperature/trip computer display mode the STEP button (2) is used to scroll through and make selections in the Trip Functions. Pressing and releasing the RESET button (4) resets the trip computer screen displayed at that time. EVIC DISPLAY MODES SYSTEM STATUS MODE Displays warnings and user interaction messages. Critical text warnings will be displayed until the failure is corrected. Non-critical text warnings will be displayed for 60 seconds. The driver can scroll to view multiple messages by using the STEP button. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 9733 When the appropriate conditions exist, the EVIC displays the following messages: - TURN SIGNALS ON (with a continuous warning chime) - RKE BATTERY LOW (with a single chime) - PERSONAL SETTINGS NOT AVAILABLE - Vehicle Not in Park - LEFT/RIGHT FRONT DOOR AJAR (one or more, with a single chime if speed is above 1 mph) - LEFT/RIGHT REAR DOOR AJAR (one or more, with a single chime if speed is above 1 mph) - DOOR(S) AJAR (with a single chime if vehicle is in motion) - LOW WASHER FLUID (with a single chime) - SERVICE PARK ASSIST SYSTEM (with a single chime) - OIL CHANGE REQUIRED (with single chime) - LEFT FRONT TURN LAMP OUT - RIGHT FRONT TURN LAMP OUT - LEFT REAR TURN LAMP OUT - RIGHT REAR TURN LAMP OUT - SERVICE PARK ASSIST SYSTEM - COOLANT LOW - ESP SYSTEM DEACTIVATED - LIFTGATE OPEN PERSONAL SETTINGS MODE (CUSTOMER PROGRAMMABLE FEATURES) Allows the driver to set and recall features when the transmission is in PARK by pressing and releasing the MENU button until Personal Settings is displayed in the EVIC. If the transmission is not in PARK the EVIC will display NOT AVAILABLE and VEHICLE NOT IN PARK. The following personal settings can be set and recalled by pressing the STEP button: - "LANGUAGE" - When in this display you may select one of three languages for all display nomenclature, including the trip functions. Press the RESET button while in this display to select English, Espanol, or Francais. Then, as you continue, the information will display in the selected language. - "AUTO DOOR LOCKS > YES" - When ON is selected, all doors will lock automatically when the vehicle reaches a speed of 15 mph (24 km/h). To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "AUTO UNLOCK ON EXIT > YES" - When ON is selected, all doors will unlock when the vehicle is stopped and the transmission is in the P (Park) or N (Neutral) position and the driver's door is opened. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "RKE UNLOCK DRV DR 1st" - When DRV DR 1st is selected, only the driver's door will unlock on the first press of the remote keyless entry unlock button. When Driver Door 1st Press is selected, you must press of the remote keyless entry unlock button twice to unlock the passenger's doors. To make your selection, press and release the RESET button until "DRV DR 1st " appears. - "RKE UNLOCK ALL DR 1ST" - When All ALL DR 1ST is selected, all of the doors will unlock on the first press of the remote keyless entry unlock button. To make your selection, press and release the RESET button until "All DR 1st" appears. - "MEM RECALL WITH RKE > YES" - When ON is selected, pressing the unlock button on the RKE will recall the memory settings for the seat, mirror and radio. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "SOUND HORN W/LOCK > YES" - When ON is selected, a short horn sound will occur when the remote keyless entry "Lock" button is pressed. This feature may be selected with or without the flash lights on lock/unlock feature. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "FLASH LAMPS w/LOCK > YES" - When ON is selected, the front and rear turn signals will flash when the doors are locked or unlocked with the remote keyless entry transmitter. This feature may be selected with or without the sound horn on lock feature selected. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "HEAD LAMP OFF DELAY > 0 SEC" - When this feature is selected, the driver can choose to have the headlights remain on for 0, 30, 60, or 90 seconds when exiting the vehicle. To make your selection, press and release the RESET button until "0," "30," "60," or "90" appears.NOTE: The head lamp switch must be in the "A" auto mode for this feature to work. - HEADLAMPS W /WIPERS > YES - When ON is selected, the headlamps will automatically turn on when the wiper switch is activated. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - EASY EXIT SEAT > YES - When ON is selected, and the key is removed from the ignition, the driver's seat will automatically move rearward to allow easy exit. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - TILT MIRRORS IN "R" > YES - When On is selected, and the transmission is put in reverse, the outside mirrors will tilt downward. To make your selection, press and release the RESET button until "ON" or "OFF" appears. - "KEY OFF POWER DELAY > OFF" - When this feature is selected, the power window switches, radio, hands-free system (if equipped), DVD video system (if equipped) and power outlets will remain active for up to 60 minutes after the ignition switch is turned off. Opening a vehicle door will cancel this feature. To make your selection, press and release the RESET button until "Off," "45 sec.," "5 min.," "10 min." appears. - "ILLUMINATED APRCH > OFF" - When this feature is selected, the headlights will activate and remain on for up to 90 seconds when the doors are unlocked with the remote keyless entry transmitter. To make your selection, press and release the RESET button until "OFF," "30 sec.," "60 sec.," or "90 sec." appears. - PARK ASST. SYSTEM > YES - When YES is selected, the Park Assist System is activated when the vehicle is in Reverse. When No is selected, the Rear Park System is turned off. To make your selection, press and release the RESET button until "ON" or "OFF" appears. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Liftgate Ajar Indicator - Description > Page 9734 - "UNIT IN > US/METRIC" - The EVIC, odometer can be changed between English and Metric units of measure. To make your selection, press and release the RESET button until "US" or "METRIC" appears. - "COMPASS VARIANCE > 1" - Press the RESET button to change the compass variance setting. See: Adjustments for additional information. - "COMPASS CALIBRATE > YES" - Press the RESET button to calibrate the compass. See: Adjustments for additional information. COMPASS/TEMPERATURE/TRIP COMPUTER MODE This display provides the outside temperature, one of the eight compass headings to indicate the direction the vehicle is facing, and vehicle trip information. The compass and temperature display is the normal display. When the C/T button is pressed the EVIC returns to the compass/temperature display from all other functions. The trip computer function will be displayed if the STEP button is pressed from the Compass/Temperature display mode. The trip computer displays the following information: - TRIP - Shows the total distance traveled since the last reset. To reset the TRIP function, press and hold the RESET button. - ELAPSED TIME - Shows the total elapsed time of travel since the last reset. Elapsed time will increment when the ignition switch is in the ON/RUN or START positions. - UNIT IN US/METRIC - Press the RESET button to toggle between US and METRIC. - AVG. MPG - Shows the average fuel economy since the last reset. When the fuel economy is reset, the display will show dashes for two seconds. Then the history information will be erased, and the averaging will continue from the last fuel average reading before the reset. (Example: If your Electronic Vehicle Information Center (EVIC) displays 18 AVG. MPG and the RESET button is pressed, the previous averaging history will be erased and the display will return to the 18 AVG. MPG, not to 0 AVG. MPG). The display may take several miles for the value to change dependent upon driving habits. - MI TO EMPTY (Distance To Empty) - Shows the estimated distance that can be traveled with the fuel remaining in the tank. This estimated distance is determined by a weighted average of fuel economy, according to the current fuel tank level. Distance MI TO EMPTY cannot be reset through the RESET button. When the DTE value is less than 30 miles (48 km) estimated driving distance, the DTE display will change to a text display of "LOW FUEL." This display will continue until the vehicle runs out of fuel. Adding a significant amount of fuel to the vehicle will turn off the "LOW FUEL" text and a new DTE value will display. UNIVERSAL GARAGE DOOR (HOMELINK(R)) TRANSCEIVER The EVIC features a driver-interactive display which includes HomeLink(R) system messages. For additional information on the HomeLink(R) transceiver See: Accessories and Optional Equipment/Garage Door Opener Transmitter/Description and Operation/Universal Transmitter Description. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 9735 Driver/Vehicle Information Display: Testing and Inspection ELECTRONIC VEHICLE INFORMATION CENTER The Electronic Vehicle Information Center (EVIC) data is obtained from several components on the Controller Area Network (CAN) data bus circuit. The EVIC will not function properly if the bus messages from any of these components is not received. If no EVIC data is displayed, check the CAN data bus circuit communications, the instrument cluster also known as Cab Compartment Node (CCN) functions and the Integrated Power Module (IPM). If the problem with the EVIC is an inaccurate or scrambled display, refer to theSELF- DIAGNOSTIC TEST. If the problem with the EVIC is incorrect Vacuum Fluorescent Display (VFD) dimming levels, use a scan tool and the proper diagnostic procedures information to test for the correct dimming message inputs being received from the CCN or TIPM over the CAN data bus circuit. If the problem is a no-display condition, use the following procedure. For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and harness connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Remove the overhead console from the headliner. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 2. Inspect the Ignition Off Draw (IOD) fuse in the IPM. If the IOD fuse is ok and in place, go to 3. If not ok, repair the open IOD fuse circuit as required. 3. Check for battery voltage at the overhead console electrical connector. If ok, go to 4. If not ok, check for battery voltage at the appropriate B(+) fuse in the IPM. Repair the open fused B(+) circuit as required. 4. Turn the ignition switch to the On position. Check the fused ignition switch output circuit(s) at the overhead console electrical connector. If ok, go to 5. If not ok, repair the open or shorted circuit as required. 5. Turn the ignition switch to the Off position. Disconnect and isolate the negative battery cable. Check for continuity between the ground circuit cavity of the overhead console electrical connector and a good ground. There should be continuity. If ok, refer to theSELF- DIAGNOSTIC TEST for further diagnosis of the EVIC module and the CAN data bus circuit. If not ok, repair the open ground circuit as required. SELF- DIAGNOSTIC TEST NOTE: The EVIC Self-Test can also be performed using a scan tool. Navigate to the Auto Self-Test screen under System Tests of the scan tool and initiate the EVIC Self-Test. A self-diagnostic test is used to determine that the EVIC is operating properly electrically. Initiate the self-diagnostic test as follows: 1. With the ignition switch in the Off position, simultaneously press and hold the STEP and RESET buttons while rotating the ignition switch to the Run/On position. 2. Continue to hold both buttons pressed until the EVIC enters the display segment test. In this test, all of the Vacuum Fluorescent Display (VFD) segments are lighted while the EVIC performs the following checks: Non-Volatile Memory Status (NVM) - RAM Status - ROM Status - ASIC Communication Status - Compass Status - DC Status - CAN Data Bus Communications Status NOTE: If the EVIC module is equipped with the universal transmitter (also known as HomeLink(R)), the module also checks HomeLink(R) communication test status. 3. Following completion of these tests, the EVIC displays one of two messages: "Self Test: FAIL" or "Self Test: PASS." In addition to the FAIL/PASS message the EVIC displays the current software version (SW V xx.xx.xxx) below the FAIL/PASS info. Press the RESET or STEP button to exit and enter normal mode. Respond to these test results as follows: If no test result message displays, but EVIC operation is still improper, Use a scan tool and the proper diagnostic procedures information are required for further diagnosis. - If the "Self Test: FAIL" message displays, the EVIC is inoperative and must be replaced. - If the "Self Test: PASS" message displays, the EVIC is ok, no faults are present. - If any VFD segment does not light during the display segment test, the EVIC is inoperative and must be replaced. If the first seven tests pass, the EVIC verifies that all the required CAN bus messages are present on the CAN bus. If all required messages are present on the CAN bus, the EVIC automatically returns to normal operation after sixty seconds. The EVIC can also be returned to normal operation anytime during the test by pressing the STEP, C/T, RESET or US/M buttons. NOTE: Pressing the STEP or RESET buttons during any portion of the EVIC Self - Diagnostic Test procedure causes the EVIC to exit diagnostics Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Description and Operation > Page 9736 and return to compass/temperature mode. NOTE: If the compass functions, but accuracy is suspect, it may be necessary to perform a variance adjustment. This procedure allows the compass unit to accommodate variations in the earths magnetic field strength based on geographic location. NOTE: If the compass reading blanks out, and only "CAL" appears in the display, demagnetizing may be necessary to remove excessive residual magnetic fields from the vehicle. Check for stored Diagnostic Trouble Codes (DTCs) and follow the proper diagnostic procedures information as needed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration Driver/Vehicle Information Display: Adjustments Manual Compass Calibration MANUAL COMPASS CALIBRATION CAUTION: Do not place any external magnets, such as magnetic roof mount antennas, in the vicinity of the overhead console. Do not use magnetic tools when servicing the overhead console. NOTE: Whenever the compass is calibrated manually, the variance number must also be reset. See: for the appropriate procedure. The electronic compass unit features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use. If the compass readings appear to be erratic or the Electronic Vehicle Information Center (EVIC) displays "CAL", perform the following manual calibration procedure. Also, any time EVIC service replacement components are installed, they must be calibrated using this procedure. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings, or bridges; or, near overhead or underground power lines. Calibrate the compass manually as follows: 1. Turn the ignition switch to the On/Run position. Press and release the MENU push button (1) until "Personal Settings" is displayed. 2. Press the STEP push button (2) until "Calibrate Compass YES" is displayed. 3. Momentarily depress and release the RESET push button (4) to initiate the calibration procedure. The message "CAL will appear in the Compass/Temperature display. 4. Slowly drive the vehicle on a level surface, away from large metal objects and power lines, through one or two complete circles not exceeding 8 km/h (5 mph). The "CAL" message will disappear from the display to indicate that the compass is now calibrated. NOTE: A blank compass display indicates that vehicle degaussing (demagnetizing) may be necessary. NOTE: If the "CAL" message remains in the display, either there is excessive magnetism near the compass, or the EVIC is inoperative. Attempt the calibration procedure at least one more time before performing EVIC diagnosis. NOTE: If the wrong direction is still indicated in the compass display, the area selected for calibration may be too close to a strong magnetic field. Repeat the manual calibration procedure in another location. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration > Page 9739 Driver/Vehicle Information Display: Adjustments Compass Variance Adjustment COMPASS VARIANCE ADJUSTMENT Variance Settings Map Compass variance, also known as magnetic declination, is the difference in angle between magnetic north and true geographic north. In some geographic locations, the difference between magnetic and geographic north is great enough to cause the compass to give false readings. If this problem occurs, the compass variance must be set. NOTE: If the vehicle is taken on long trips into a new variance zone the compass function may be effected. Compass variance may need to be adjusted to the new zone number to function properly. NOTE: The default for the compass variance from the factory is 8. To set the compass variance: 1. Using the Variance Settings Map, find your geographic location and note the zone number. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Adjustments > Manual Compass Calibration > Page 9740 2. Turn the ignition switch to the On/Run position. Press and release the MENU push button (1) until "Personal Settings" is displayed. 3. Press the STEP push button (2) until "Compass Variance" is displayed. 4. Momentarily depress and release the RESET push button (4) to toggle through the zone numbers (1-15), until the zone number for your geographic location appears in the display. 5. Momentarily depress and release the C/T push button (5) to enter the displayed zone number into the compass unit memory. 6. Confirm that the correct directions are now indicated by the compass. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures COMPASS DEMAGNETIZING A degaussing tool (Special Tool 6029) is used to demagnetize, or degauss, the overhead console forward mounting screw and the roof panel above the overhead console. Equivalent units must be rated as continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: 1. Be certain that the ignition switch is in the Off position, before you begin the demagnetizing procedure. 2. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 3. Slowly approach the head of the overhead console forward mounting screw with the degaussing tool connected. 4. Contact the head of the screw with the plastic coated tip of the degaussing tool for about two seconds. 5. With the degaussing tool still energized, slowly back it away from the screw. When the tip of the tool is at least 61 centimeters (2 feet) from the screw head, disconnect the tool. To demagnetize the roof panel proceed as follows: 6. Place a piece of paper approximately 22 by 28 centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of the roof at the windshield header. The purpose of the paper is to protect the roof panel from scratches, and to define the area to be demagnetized. 7. Connect the degaussing tool to an electrical outlet, while keeping the tool at least 61 centimeters (2 feet) away from the compass unit. 8. Slowly approach the center line of the roof panel at the windshield header, with the degaussing tool connected. 9. Contact the roof panel with the plastic coated tip of the degaussing tool. Be sure that the template is in place to avoid scratching the roof panel. Using a slow, back-and-forth sweeping motion, and allowing 13 millimeters (0.50 inch) between passes, move the tool at least 11 centimeters (4 inches) to each side of the roof center line, and 28 centimeters (11 inches) back from the windshield header. 10. With the degaussing tool still energized, slowly back it away from the roof panel. When the tip of the tool is at least 61 centimeters (2 feet) from the roof panel, disconnect the tool. 11. Calibrate the compass and adjust the compass variance, See: Compass/Adjustments/Compass Variance Adjustment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 9743 Driver/Vehicle Information Display: Removal and Replacement Electronic Vehicle Information Center - Removal ELECTRONIC VEHICLE INFORMATION CENTER 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console from the headliner, See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Remove the screws (1) that secure the Electronic Vehicle Information Center (EVIC) (2) to the overhead console housing (3). 4. Remove the EVIC from the overhead console housing. Electronic Vehicle Information Center - Installation ELECTRONIC VEHICLE INFORMATION CENTER NOTE: If a new Electronic Vehicle Information Center (EVIC) has been installed, the compass will have to be calibrated and the variance set. See: Adjustments and See: Adjustments for the appropriate procedures. 1. Position the Electronic Vehicle Information Center (EVIC) (2) onto the overhead console housing (3). 2. Install the screws (1) that secure the EVIC (2) to the overhead console housing (3). Tighten the screws to 2 Nm (20 in. lbs.). 3. Install the overhead console onto the headliner, See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console Installation. 4. Reconnect the battery negative cable. Electronic Vehicle Information Center Control Bulb - Removal BULB - EVIC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 9744 attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. NOTE: There are provisions for up to four bulb/bulb holder units on the Electronic Vehicle Information Center (EVIC) circuit board. The two outboard bulbs illuminate the EVIC push buttons, while the two center bulbs illuminate the optional universal transmitter push buttons. Therefore, the center bulb locations are only populated on vehicles equipped with the optional universal transmitter. 1. Disconnect and isolate the battery negative cable. 2. Remove the overhead console (1) from the headliner. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Use a small thin-bladed screwdriver to rotate the bulb holder (3) counterclockwise about 30 degrees to unlock it from the keyed opening in the Electronic Vehicle Information Center (EVIC) unit (2) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. Electronic Vehicle Information Center Control Bulb - Installation BULB - EVIC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: There are provisions for up to four bulb/bulb holder units on the Electronic Vehicle Information Center (EVIC) circuit board. The two outboard bulbs illuminate the EVIC push buttons, while the two center bulbs illuminate the optional universal transmitter push buttons. Therefore, the center bulb locations are only populated on vehicles equipped with the optional universal transmitter. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 9745 1. Align the bulb holder and bulb (3) with the keyed opening in the circuit board of the Electronic Vehicle Information Center (EVIC) (2). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the overhead console (1) onto the headliner. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Installation. 5. Reconnect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Page 9746 Driver/Vehicle Information Display: Tools and Equipment ELECTRONIC VEHICLE INFORMATION CENTER Degaussing Tool 6029 Radio Frequency Detector 9001 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Electronic Throttle Control Indicator > Component Information > Description and Operation > ETC Indicator - Description Electronic Throttle Control Indicator: Description and Operation ETC Indicator - Description DESCRIPTION An Electronic Throttle Control (ETC) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with ETC, this indicator is electronically disabled. This indicator is located in the center of the speedometer, in the area to the right of the speedometer needle hub. The ETC indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Electronic Throttle Control in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ETC indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Electronic Throttle Control Indicator > Component Information > Description and Operation > ETC Indicator - Description > Page 9751 Electronic Throttle Control Indicator: Description and Operation ETC Indicator - Operation OPERATION The Electronic Throttle Control (ETC) indicator gives an indication to the vehicle operator when the ETC system, or a circuit or component of the system is ineffective. The ETC indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The ETC indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the ETC indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the ETC indicator illuminates for about 15 seconds. The entire bulb test is a function of the PCM. - ETC Indicator Lamp-On Message - Each time the cluster receives an electronic ETC indicator lamp-on message from the PCM, the ETC indicator illuminates. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM message. The indicator remains illuminated solid or continues to flash for about 12 seconds or until the cluster receives a lamp-off message from the PCM, whichever is longer. If the indicator is illuminated solid with the engine running the vehicle will usually remain drivable. If the indicator is flashing with the engine running the vehicle may require towing. A flashing indicator means the ETC system requires immediate service. The indicator is extinguished when the ignition switch turns to the off position. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the PCM for three consecutive seconds, the ETC indicator illuminates. The indicator remains illuminated until the cluster receives a single lamp-off message from the PCM. - Self Test - Each time the cluster is put through the self test, the ETC indicator is turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The actuator test illumination of the ETC indicator is a function of the PCM. The PCM continually monitors the ETC system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the PCM sends a lamp-on message after the bulb test, it indicates that the PCM has detected an ETC system malfunction or that the ETC system is ineffective. The PCM stores a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the ETC indicator fails to illuminate due to an open or short in the cluster ETC indicator circuit, the cluster sends a message notifying the PCM of the condition, then the instrument cluster and the PCM will each store a DTC. Using a diagnostic scan tool for proper diagnosis of the ETC system, the PCM, the CCN, the CAN data bus or the electronic communication related to ETC indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fog/Driving Lamp Indicator > Component Information > Description and Operation > Fog Lamp Indicator - Description Fog/Driving Lamp Indicator: Description and Operation Fog Lamp Indicator - Description DESCRIPTION A fog lamp indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with optional fog lamps, this indicator is electronically disabled. This indicator is located within the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. The fog lamp indicator consists of the International Control and Display Symbol icon for Front Fog Light in the lower left corner of the VFD unit. The VFD unit is soldered onto the instrument cluster electronic circuit board, and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the icon from being clearly visible when it is not illuminated. The fog lamp indicator icon appears in a blue-green color and at the same lighting level as the odometer information when it is illuminated by the instrument cluster electronic circuit board. During daylight hours (exterior lamps are OFF) the VFD unit is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the VFD unit lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer function of the interior lighting thumbwheel on the headlamp switch. However, a PARADE mode position of the thumbwheel allows the VFD unit to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The fog lamp indicator is serviced as a unit with the VFD unit in the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fog/Driving Lamp Indicator > Component Information > Description and Operation > Fog Lamp Indicator - Description > Page 9756 Fog/Driving Lamp Indicator: Description and Operation Fog Lamp Indicator - Operation OPERATION The fog lamp indicator gives an indication to the vehicle operator whenever the optional fog lamps are illuminated. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The fog lamp indicator is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate whenever the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator is always off when the ignition switch is in any position except ON or START. The indicator only illuminates when it is energized by the instrument cluster logic circuit. The instrument cluster turns on the fog lamp indicator for the following reasons: - Fog Indicator Lamp-On Message - Each time the cluster receives an electronic fog indicator lamp-on message from the FCM indicating the fog lamp relay is energized, the fog lamp indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-OFF message from the FCM, until the ignition switch is turned to the OFF position or until the exterior lamp load shedding (battery saver) timed interval expires, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the fog lamp indicator turns on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The FCM continually monitors electronic exterior lighting switch status messages from the instrument cluster, also known as the Cab Compartment Node (CCN) to determine the appropriate outputs to the fog lamp relay. The FCM activates or deactivates the fog lamp relay then sends the proper lamp-on or lamp-off message back to the CCN. For further diagnosis of the fog lamp indicator or the instrument cluster circuitry that controls the indicator, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the fog lamp system, the FCM, the CCN, the CAN data bus or the electronic communication related to fog lamp indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description Four Wheel Drive Indicator Lamp: Description and Operation 4WD Indicator - Description 4WD INDICATOR A 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD indicator is located below the minor gauge set on the left side of the cluster. The 4WD indicator consists of a stencil-like cutout of the text 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 9761 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Low Indicator - Description 4WD LOW INDICATOR A 4WD low indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. The 4WD low indicator is located below the minor gauge set on the left side of the cluster. The 4WD low indicator consists of a stencil-like cutout of the text 4LOW in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the 4WD low indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The 4WD low indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 9762 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Indicator - Operation 4WD INDICATOR The 4WD indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into a 4WD mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the 4WD indicator for the following reasons: - 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic 4WD indicator lamp-on message from the FCM, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the 4WD indicator will be turned ON, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD mode is engaged. The FCM then sends the proper lamp-on or lamp-off message to the instrument cluster also known as the Cab Compartment Node (CCN). For further diagnosis of the 4WD indicator or the instrument cluster circuitry that controls the LED, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transfer case shift motor/mode sensor, the FCM, the CCN, the CAN data bus or the electronic communication related to 4WD indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4WD Indicator - Description > Page 9763 Four Wheel Drive Indicator Lamp: Description and Operation 4WD Low Indicator - Operation 4WD LOW INDICATOR The 4WD low indicator gives an indication to the vehicle operator when the electronic transfer case has been shifted into the 4WD low mode. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The 4WD low indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the 4WD low indicator for the following reasons: - 4WD Low Indicator Lamp-On Message- Each time the cluster receives an electronic 4WD low indicator lamp-on message from the FCM, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the 4WD low indicator turns on, then off again during the LED portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case through the transfer case shift motor/mode sensor assembly to determine when the 4WD low mode is engaged. The FCM then sends the proper lamp-on or lamp-off message to the Instrument Cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the 4WD low indicator or the instrument cluster circuitry that controls the LED, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transfer case shift motor/mode sensor, the FCM, the CCN, the CAN data bus or the electronic communication related to 4WD low indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator > Component Information > Description and Operation > Gas Cap Indicator - Description Fuel Filler Cap Warning Indicator: Description and Operation Gas Cap Indicator - Description DESCRIPTION A gas cap indicator is standard equipment on all instrument clusters. The gas cap indication appears within the odometer Vacuum Fluorescent Display (VFD) unit. The gas cap indicator consists of a textual GASCAP message which appears in place of the odometer/trip odometer information in the display. The odometer VFD is soldered onto the cluster electronic circuit board, and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The gas cap textual message appears in the same blue-green color and at the same lighting level as the odometer/trip odometer information when illuminated by the instrument cluster electronic circuit board. The gas cap indicator is serviced as a unit with the VFD in the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Filler Cap Warning Indicator > Component Information > Description and Operation > Gas Cap Indicator - Description > Page 9768 Fuel Filler Cap Warning Indicator: Description and Operation Gas Cap Indicator - Operation OPERATION The gas cap indicator gives an indication to the vehicle operator when there is a gross leak detected in the on board fuel vapor recovery system. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the Powertrain Control Module (PCM). The gas cap indicator function of the odometer Vacuum Fluorescent Display (VFD) unit is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the VFD gas cap indication is always off when the ignition switch is in any position except ON or START. The instrument cluster turns on the gas cap indicator for the following reasons: - Gas Cap Indicator Lamp-On Message - Each time the cluster receives an electronic gas cap indicator lamp-on message from the PCM indicating there is a gross leak in the vapor recovery system, the gas cap indicator illuminates. If the ignition switch is in the ON position and the vehicle is not moving when the message is received, the VFD repeatedly and sequentially cycles the gas cap indication in two second intervals with the odometer/trip odometer information and any other active textual warnings. If the vehicle is moving, or once the cluster of a non-moving vehicle receives an electronic vehicle speed message from the PCM indicating a speed greater than zero, the warning sequence consists of three complete display cycles with an audible single chime tone accompanying each cycle, then revert to only the visual gas cap indication and odometer/trip odometer display cycling until the cluster receives a message indicating there is no gross leak in the vapor recovery system, or until the ignition switch turns to the off position, whichever occurs first. The VFD can be reverted to the odometer display and any currently displayed textual messages suspended by momentarily depressing and releasing the odometer/trip odometer reset switch button on the front of the cluster. The PCM continually monitors the on board vapor recovery system to determine whether there are air leaks in the system. The PCM then sends the proper electronic messages to the instrument cluster, also known as the Cab Compartment Node (CCN). If the CCN turns on the gas cap indicator due to a monitored gross leak in the vapor recovery system, it may indicate that the gas cap has been removed or is improperly installed. Use a diagnostic scan tool for proper diagnosis of the on board vapor recovery system, the PCM, the CCN, the CAN data bus or the electronic communication related to gas cap indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Fuel Gauge - Description Fuel Gauge: Description and Operation Fuel Gauge - Description DESCRIPTION A fuel gauge is standard equipment on all instrument clusters. This gauge is part of the minor gauge set with the engine coolant temperature gauge located on the left side of the instrument cluster, just left of the speedometer. This gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree gauge scale on the cluster overlay that reads bottom-to-top from E (or Empty) to F (or Full). An International Control and Display Symbol icon for Fuel is located on the cluster overlay, in the center of the gauge directly below the bottom end of the scale. An arrowhead pointed to the left side of the vehicle is imprinted on the cluster overlay next to the Fuel icon on the gauge to provide the driver with a reminder as to the location of the fuel filler access. The fuel gauge graphics are black against a white field except for a single red graduation at the low end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the white gauge dial face appears blue-green with the black graphics silhouetted against the illuminated background and the red graphics and the red gauge needle still appear red. Gauge illumination is provided by an integral electro-luminescent lamp that is serviced as a unit with the instrument cluster. The fuel gauge is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Fuel Gauge - Description > Page 9773 Fuel Gauge: Description and Operation Fuel Gauge - Operation OPERATION The fuel gauge gives an indication to the vehicle operator of the level of fuel in the fuel tank. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and a hardwired input received by the cluster from the fuel level sending unit on the fuel pump module in the fuel tank. The fuel gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch turns to the off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Fuel Level Sending Unit Input - The cluster provides a constant current source to the fuel level sending unit and monitors a return input on a fuel level sense circuit. The resistance through the fuel level sending unit increases as the fuel level falls and decreases as the fuel level rises causing changes in the fuel level sense input voltage. The cluster programming applies an algorithm to calculate the proper fuel gauge needle position based upon the fuel level sense input, then moves the gauge needle to the proper relative position on the gauge scale. This algorithm is used to dampen gauge needle movement against the negative effect that fuel sloshing within the fuel tank can have on accurate inputs from the fuel tank sending unit to the cluster. - Less Than 15 Percent Tank Full Input - Each time the fuel level sense input to the cluster indicates the fuel tank is about 15 percent full or less for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, the gauge needle moves to about the one-sixteenth graduation on the gauge scale, the low fuel indicator illuminates, and a single chime tone is sounded. The low fuel indicator remains illuminated until the fuel level sense input indicates that the fuel tank is greater than about 15 percent full for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, or until the ignition switch turns to the off position, whichever occurs first. The chime tone feature only repeats during the same ignition cycle if the low fuel indicator is cycled off then on again by the appropriate inputs from the fuel level sending unit. - Less Than Empty Stop Input - Each time the cluster receives a fuel level sense input that indicates the fuel level in the fuel tank is less than the Empty gauge needle stop position, the gauge needle moves to the low end of the gauge scale and the low fuel indicator illuminates immediately. This input would indicate that the fuel level sense input to the cluster is a short circuit. - More Than Full Stop Input - Each time the cluster receives a fuel level sense input that indicates the fuel level in the fuel tank is more than the Full gauge needle stop position, the gauge needle moves to the low end of the gauge scale and the low fuel indicator illuminates immediately. This input would indicate that the fuel level sense input to the cluster is an open circuit. - Self Test - Each time the cluster is put through the self test, the fuel gauge needle is swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The instrument cluster, also known as the Cab Compartment Node (CCN) continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. The CCN then sends the proper electronic fuel level messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. For further diagnosis of the fuel gauge or the instrument cluster circuitry that controls the gauge, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the fuel tank sending unit, the CCN, the CAN data bus or the electronic communication related to fuel gauge operation or fuel level data processing. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 9777 Fuel Gauge Sender: Diagrams Connector - (CHASSIS) 4 WAY MODULE-FUEL PUMP - (CHASSIS) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 9778 Fuel Gauge Sender: Description and Operation DESCRIPTION The fuel pump module assembly (4) is located on the top of the fuel tank (2). The module assembly (5) contains the following components: - An internal fuel filter - A separate fuel pick-up, or inlet filter (3) - A fuel pressure regulator (4) - An electric fuel pump (2) - A lock ring to retain pump module to tank - A soft gasket between tank flange and module - A fuel gauge sending unit (fuel level sensor) (1) - Fuel line connection (6) If the fuel gauge sending unit, electrical fuel pump, primary inlet filter, fuel filter or fuel pressure regulator require service, the fuel pump module must be replaced. Electric Fuel Pump The electric fuel pump is located inside of the fuel pump module. A 12 volt, permanent magnet, electric motor powers the fuel pump. The electric fuel pump is not a separate, serviceable component. Fuel Filters Two fuel filters are used. One is located at the bottom of the fuel pump module. The other is located inside the module. A separate frame mounted fuel filter is not used with any engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Locations > Page 9779 Both fuel filters are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator The fuel pressure regulator is located within fuel pump module. Fuel Gauge Sending Unit (Fuel level sensor) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Gauge Sender: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: The fuel system is under a constant pressure, even with the engine off. Before servicing the fuel pump module, the fuel system pressure must be released. 1. Perform the fuel system pressure release procedure See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Disconnect and isolate the negative battery cable. 3. Drain and remove the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal 4. Note the rotational position of the module before attempting removal. An indexing arrow is located on top of the module for this purpose. 5. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 6. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 7. Rotate the breaker bar counterclockwise to remove the lock ring. 8. Remove the lock ring. The module will spring up slightly when the lock ring is removed. 9. Remove the module from the fuel tank. Be careful not to bend the float arm during removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9782 Fuel Gauge Sender: Service and Repair Fuel Pump Module - Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position the fuel pump module into the opening of the fuel tank. 2. Rotate the module until the embossed alignment arrow points to the center alignment mark. This step must be performed to prevent the float from contacting the side of the fuel tank. Also be sure the fuel fitting on top of the pump module is pointed to the left side of the vehicle. 3. Position the lock ring (5) over the top of the fuel pump module. 4. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 5. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 6. Tighten the lock ring (clockwise) until all seven notches have engaged. 7. Install the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation 8. Lower the vehicle. 9. Connect the fuel line quick connect fitting to the fuel rail (1)See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair 10. Connect the negative battery cable. 11. Install the fuel fill cap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Illumination Lamp - Removal Instrument Panel Bulb: Service and Repair Illumination Lamp - Removal EVIC Control BULB - EVIC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: There are provisions for up to four bulb/bulb holder units on the Electronic Vehicle Information Center (EVIC) circuit board. The two outboard bulbs illuminate the EVIC push buttons, while the two center bulbs illuminate the universal transmitter push buttons. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the overhead console (1) from the headliner. See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Removal. 3. Use a small thin-bladed screwdriver to rotate the bulb holder (3) counterclockwise about 30 degrees to unlock it from the keyed opening in the Electronic Vehicle Information Center (EVIC) (2) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. Front A/C-Heat Control BULB - FRONT A/C-HEAT CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Illumination Lamp - Removal > Page 9788 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the center bezel (1) from the instrument panel. See: Dashboard / Instrument Panel/Service and Repair/Instrument Panel Bezel - Removal. 3. Use a small thin-bladed screwdriver to rotate the bulb holder (3) counterclockwise about 30 degrees to unlock it from the keyed opening in the front A/C-heater control (2) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. Rear A/C-Heat Control BULB - REAR A/C-HEAT CONTROL 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the rear A/C-heater control from the center floor console. See: Heating and Air Conditioning/Control Assembly/Service and Repair/A/C and Heater Control - Removal. 3. Use a small thin-bladed screwdriver to rotate the bulb holder (2) counterclockwise about 30 degrees to unlock it from the keyed opening in rear A/C-heater control (1) circuit board. 4. Pull the bulb holder and bulb straight out of the circuit board. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Illumination Lamp - Removal > Page 9789 Instrument Panel Bulb: Service and Repair Illumination Lamp - Installation EVIC Control BULB - EVIC CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: There are provisions for up to four bulb/bulb holder units on the Electronic Vehicle Information Center (EVIC) circuit board. The two outboard bulbs illuminate the EVIC push buttons, while the two center bulbs illuminate the universal transmitter push buttons. 1. Align the bulb holder and bulb (3) with the keyed opening in the circuit board of the Electronic Vehicle Information Center (EVIC) (2). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the overhead console (1) onto the headliner. . See: Body and Frame/Interior Moulding / Trim/Console/Service and Repair/Overhead Console - Installation 5. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Front A/C-Heat Control BULB - FRONT A/C-HEAT CONTROL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair > Illumination Lamp - Removal > Page 9790 1. Align the bulb holder and bulb (3) with the keyed opening in the circuit board of the front A/C-heater control (2). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the center bezel (1) onto the instrument panel. See: Dashboard / Instrument Panel/Service and Repair/Instrument Cluster Bezel Installation. 5. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Rear A/C-Heat Control BULB - REAR A/C-HEAT CONTROL CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the bulb holder and bulb (2) with the keyed opening in the circuit board of the rear A/C-heater control (1). 2. Insert the bulb holder and bulb straight into the circuit board until the bulb holder is firmly seated. 3. Using a small thin-bladed screwdriver, rotate the bulb holder clockwise about 30 degrees on the circuit board to lock it into place. 4. Reinstall the rear A/C-heater control onto the center floor console. See: Heating and Air Conditioning/Control Assembly/Service and Repair/A/C and Heater Control - Installation. 5. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect install the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Low Fuel Indicator - Description Low Fuel Lamp/Indicator: Description and Operation Low Fuel Indicator - Description DESCRIPTION A low fuel indicator is standard equipment on all instrument clusters. This indicator is located near the upper edge of the instrument cluster, between the minor gauge set and the speedometer. The low fuel indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Fuel in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The low fuel indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Low Fuel Indicator - Description > Page 9795 Low Fuel Lamp/Indicator: Description and Operation Low Fuel Indicator - Operation OPERATION The low fuel indicator gives an indication to the vehicle operator when the level of fuel in the fuel tank becomes low. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hardwired input received by the cluster from the fuel level sending unit on the fuel pump module in the fuel tank. The low fuel indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the low fuel indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the low fuel indicator is illuminated for about two seconds as a bulb test. - Less Than 15 Percent Tank Full Input - The cluster provides a constant current source to the fuel level sending unit and monitors a return input on a fuel level sense circuit. The resistance through the fuel level sending unit increases as the fuel level falls and decreases as the fuel level rises causing changes in the sense input voltage. Each time the fuel level sense input to the cluster indicates the fuel tank is about 15 percent full or less for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, the fuel gauge needle is moved to about the one-sixteenth graduation on the gauge scale, the low fuel indicator illuminates, and a single chime tone is sounded. The low fuel indicator remains illuminated until the fuel level sense input indicates that the fuel tank is greater than about 15 percent full for 10 consecutive seconds and the vehicle speed is zero, or for 60 consecutive seconds and the vehicle speed is greater than zero, or until the ignition switch turns to the OFF position, whichever occurs first. The chime tone feature only repeats during the same ignition cycle if the low fuel indicator is cycled off then on again by the appropriate inputs from the fuel level sending unit. - Less Than Empty Stop Input - Each time the cluster receives a fuel level sense input that indicates the fuel level in the fuel tank is less than the E (or Empty) gauge needle stop position, the gauge needle moves to the low end of the gauge scale and the low fuel indicator illuminates immediately. This input would indicate that the fuel level sense input to the cluster is a short circuit. - More Than Full Stop Input - Each time the cluster receives a fuel level sense input that indicates the fuel level in the fuel tank is more than the F (or Full) gauge needle stop position, the gauge needle moves to the low end of the gauge scale and the low fuel indicator illuminates immediately. This input would indicate that the fuel level sense input to the cluster is an open circuit. - Self Test - Each time the cluster is put through the self test, the low fuel indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster, also known as the Cab Compartment Node, (CCN) continually monitors the fuel tank sending unit to determine the level of fuel in the fuel tank. The cluster then sends the proper electronic fuel level messages to other electronic modules in the vehicle over the Controller Area Network (CAN) data bus. For further diagnosis of the low fuel indicator or the instrument cluster circuitry that controls the LED, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the fuel tank sending unit, the CCN, the CAN data bus or the electronic communication related to low fuel indicator operation or fuel level data processing. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Indicator - Description Low Tire Pressure Indicator: Description and Operation Low Tire Pressure Indicator - Description DESCRIPTION A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the speedometer dial face to the left of the speedometer needle hub in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Indicator - Description > Page 9800 Low Tire Pressure Indicator: Description and Operation Low Tire Pressure Indicator - Operation OPERATION The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM), over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position, the SKREEM sends an electronic TPM indicator lamp-on message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Indicator Lamp-On Message - Each time the cluster receives an electronic TPM indicator lamp-on message from the SKREEM, the TPM indicator illuminates. The indicator can be flashed on and off, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a lamp-off message from the SKREEM or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-on or lamp-off messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-on or lamp-off message is received from the SKREEM. - Self Test - Each time the cluster is put through the self test, the TPM indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the ON position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or low. The SKREEM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the instrument cluster turns on the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is ineffective. Use a diagnostic scan tool for proper diagnosis of the TPM system, the SKREEM, the CCN, the CAN data bus or the electronic communication related to TPM indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Oil Change Indicator - Description Maintenance Required Lamp/Indicator: Description and Operation Oil Change Indicator Description DESCRIPTION A change oil indicator is standard equipment on all instrument clusters. However, on vehicles manufactured for export markets, this indicator is electronically disabled. This indicator is located within the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. However, on vehicles equipped with the optional Electronic Vehicle Information Center (EVIC), the change oil indicator in the odometer VFD is electronically suppressed so as not to duplicate indications that are provided by the EVIC. The change oil indicator consists of cycling textual CHAngE and OIL messages which appear in place of the odometer/trip odometer information in the odometer VFD unit. The odometer VFD is soldered onto the cluster electronic circuit board, and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The change oil textual messages appear in the same blue-green color and at the same lighting level as the odometer information when they are illuminated by the instrument cluster electronic circuit board. The change oil indicator is serviced as a unit with the VFD in the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Oil Change Indicator - Description > Page 9805 Maintenance Required Lamp/Indicator: Description and Operation Oil Change Indicator - Operation OPERATION The change oil indicator gives an indication to the vehicle operator when a duty-cycle algorithm contained within the software of the Powertrain Control Module (PCM) determines that a recommended oil change interval has been attained. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and electronic messages received over the Controller Area Network (CAN) data bus from the PCM. The change oil indicator function of the Vacuum Fluorescent Display (VFD) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the VFD change oil indication is always off when the ignition switch is in any position except ON or START. The instrument cluster turns on the change oil indicator for the following reasons: - Change Oil Indicator Lamp-On Message - Each time the ignition switch is turned to the ON position and the cluster receives an electronic change oil indicator lamp-on message from the PCM indicating that a duty-cycle based recommended oil change interval has been attained, the change oil indicator illuminates for about three seconds, until the trip odometer reset switch button is depressed, or until the ignition switch is turned to the OFF position, whichever occurs first. - Change Oil Indicator Reset Procedure - Once an engine oil change has been completed, the PCM duty cycle counters can be reset using the following procedure. Turn the ignition switch to the on position, butDo not start the engine. Slowly depress and release the accelerator pedal fully three times within ten seconds. Turn the ignition switch to the off position. If the change oil indicator illuminates the next time the engine is started, repeat this procedure. The PCM continually monitors numerous sensor inputs to determine the duty-cycles to which the engine is being subjected. A pre-programmed algorithm within the PCM then determines when to send the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). Use a diagnostic scan tool for proper diagnosis of the change oil indicator, the PCM, the CCN, the CAN data bus or the electronic communication related to change oil indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Malfunction Indicator Lamp - Description Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp - Description DESCRIPTION A Malfunction Indicator Lamp (MIL) is standard equipment on all instrument clusters. This indicator is located in the center of the speedometer, in the area to the left of the speedometer needle hub. The MIL consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The MIL is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Malfunction Indicator Lamp - Description > Page 9810 Malfunction Indicator Lamp: Description and Operation Malfunction Indicator Lamp - Operation OPERATION The Malfunction Indicator Lamp (MIL) gives an indication to the vehicle operator when the Powertrain Control Module (PCM) has recorded a Diagnostic Trouble Code (DTC) for an On-Board Diagnostics II (OBDII) emissions-related circuit or component malfunction. The MIL is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the PCM over the Controller Area Network (CAN) data bus. The MIL Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the MIL for the following reasons: - Bulb Test - Each time the ignition switch turns to the on position the indicator is illuminated for about 15 seconds as a bulb test. The entire bulb test is a function of the PCM. - MIL Lamp-On Message - Each time the cluster receives an electronic MIL lamp-on message from the PCM, the indicator illuminates. The indicator can be flashed on and off, or illuminated solid, as dictated by the PCM message. For some DTCs, if a problem does not recur, the PCM sends a lamp-off message automatically. Other DTCs may require that a fault be repaired and the PCM be reset before a lamp-off message is sent. For more information on the PCM, and the DTC set and reset parameters, See: Powertrain Management/Emission Control Systems/Testing and Inspection. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the PCM for 10 consecutive message cycles, the MIL is illuminated by the instrument cluster to indicate a loss of bus communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the PCM. - Self Test - Each time the cluster is put through the self test, the MIL indicator turns on during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the fuel and emissions system circuits and sensors to decide whether the system is in good operating condition. The PCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the MIL or the instrument cluster circuitry that controls the LED, See: Instrument Cluster / Carrier/Testing and Inspection. If the CCN turns on the MIL after the bulb test, it may indicate that a malfunction has occurred and that the fuel and emissions systems may require service. Use a diagnostic scan tool for proper diagnosis of the fuel and emissions systems, the PCM, the CCN, the CAN data bus or the electronic communication related to MIL operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp - Hybrid Drive > Component Information > Description and Operation > Hybrid Service Indicator - Description Malfunction Indicator Lamp - Hybrid Drive: Description and Operation Hybrid Service Indicator Description DESCRIPTION A Hybrid Electric Vehicle (HEV) service indicator is only found in the instrument clusters of vehicles equipped with the optional hybrid system. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The HEV service indicator consists of a stencil-like cutout of the combined International Control and Display Symbol icon for Service, call for maintenance and a lightning bolt icon for Electricity in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The HEV service indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp - Hybrid Drive > Component Information > Description and Operation > Hybrid Service Indicator - Description > Page 9815 Malfunction Indicator Lamp - Hybrid Drive: Description and Operation Hybrid Service Indicator Operation OPERATION The Hybrid Electric Vehicle (HEV) service indicator gives an indication to the vehicle operator when the Hybrid Control Processor (HCP) integral to the Traction Power Inverter Module (TPIM) has recorded a Diagnostic Trouble Code (DTC) for a hybrid systems-related circuit or component malfunction. The HEV service indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the HCP over the Controller Area Network (CAN) data bus. The HEV service indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the HEV service indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the HCP. - HEV Service Lamp-On Message - Each time the cluster receives an electronic HEV service lamp-on message from the HCP, the indicator illuminates. For some DTCs, if a problem does not recur, the HCP sends a lamp-off message automatically. Other DTCs may require that a fault be repaired and the HCP be reset before a lamp-off message is sent. - Self Test - Each time the cluster is put through the self test, the HEV service indicator will be turned ON during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The HCP continually monitors the HEV system circuits, sensors and components to decide whether the system is in good operating condition. The HCP then sends the proper lamp-on or lamp-off message to the instrument cluster also known as the Cab Compartment Node (CCN). For further diagnosis of the HEV service indicator or the instrument cluster circuitry that controls the LED, See: Instrument Cluster / Carrier/Testing and Inspection. If the CCN turns on the HEV service indicator after the bulb test, it may indicate that a malfunction has occurred and that the HEV system may require service. Use a diagnostic scan tool for proper diagnosis of the HEV system, the HCP, the CCN, the CAN data bus or the electronic communication related to HEV service indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp - Hybrid Drive > Component Information > Description and Operation > Hybrid Service Indicator - Description > Page 9816 Malfunction Indicator Lamp - Hybrid Drive: Description and Operation Regenerative Brake Indicator - Description DESCRIPTION A Regenerative Brake System (RBS) indicator is only found in the instrument clusters of vehicles equipped with the optional Hybrid Electrical Vehicle (HEV) system. This indicator is located below the minor gauge set on the left side of the cluster. The RBS indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Failure of Anti-lock Braking System in the opaque layer of the instrument cluster overlay, but with the letter R replacing the letter A in the ABS acronym. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The RBS indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp - Hybrid Drive > Component Information > Description and Operation > Hybrid Service Indicator - Description > Page 9817 Malfunction Indicator Lamp - Hybrid Drive: Description and Operation Regenerative Brake Indicator - Operation OPERATION The Regenerative Brake System (RBS) indicator gives an indication to the vehicle operator when the RBS system, or a circuit or component of the system is ineffective. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Regenerative Brake Controller (RBC) (also known as the Controller Antilock Brake/CAB) over the Controller Area Network (CAN) data bus. The RBS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the RBS indicator for the following reasons: - Bulb Test - Each time the ignition switch is turns to the on position the RBS indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the RBC. - RBS Indicator Lamp-On Message - Each time the cluster receives an electronic RBS indicator lamp-on message from the RBC, the RBS indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the RBC, or until the ignition switch turns to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-on or lamp-off messages from the RBC for five consecutive message cycles, the RBS indicator is illuminated. The indicator remains illuminated until the cluster receives a valid message from the RBC, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the instrument cluster is put through the self test, the RBS indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. - RBS Diagnostic Test - The RBS indicator is blinked on and off by lamp-on and lamp-off messages from the RBC during the performance of the RBS diagnostic tests. The RBC continually monitors the RBS circuits and sensors to decide whether the system is in good operating condition. The RBC then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the RBC sends a lamp-on message after the bulb test, it indicates that the RBC has detected a system malfunction or that the RBS system has become ineffective. The RBC stores a Diagnostic Trouble Code (DTC) for any malfunction it detects. Each time the RBS indicator fails to light due to an open or short in the cluster RBS indicator circuit, the cluster sends a message notifying the RBC of the condition, then the instrument cluster and the RBC will each store a DTC. Use a diagnostic scan tool for proper diagnosis of the regenerative brake system, the RBC, the CCN, the CAN data bus or the electronic communication related to RBS indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Service 4WD Indicator - Description Malfunction Indicator Lamp - Transfer Case: Description and Operation Service 4WD Indicator Description DESCRIPTION A service 4WD indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional four-wheel drive system and electronically shifted transfer case, this indicator is electronically disabled. This indicator is located below the minor gauge set on the left side of the cluster. The service 4WD indicator consists of a stencil-like cutout of the text SVC 4WD in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The service 4WD indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp - Transfer Case > Component Information > Description and Operation > Service 4WD Indicator - Description > Page 9822 Malfunction Indicator Lamp - Transfer Case: Description and Operation Service 4WD Indicator Operation OPERATION The service 4WD indicator gives an indication to the vehicle operator when the Front Control Module (FCM) has recorded a Diagnostic Trouble Code (DTC) for an electronic transfer case circuit or component malfunction. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the FCM over the Controller Area Network (CAN) data bus. The service 4WD indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the service 4WD indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the service 4WD indicator is illuminated for about two seconds as a bulb test. - Service 4WD Indicator Lamp-On Message - Each time the cluster receives an electronic service 4WD indicator lamp-on message from the FCM, the service 4WD indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no lamp-ON or lamp-off messages from the FCM for 10 seconds, the service 4WD indicator is illuminated by the cluster to indicate a loss of FCM communication. The indicator remains controlled and illuminated by the cluster until a valid message is received from the FCM. - Self Test - Each time the cluster is put through the self test, the service 4WD indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The FCM continually monitors the electronic transfer case control circuits and transfer case shift motor/mode sensor assembly to determine the condition of the system. The FCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the service 4WD indicator or the instrument cluster circuitry that controls the LED, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the FCM, the CCN, the CAN data bus or the electronic communication related to service 4WD indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Odometer - Description Odometer: Description and Operation Odometer - Description DESCRIPTION An odometer and trip odometer are standard factory-installed equipment in all instrument clusters. The odometer, trip odometer, and engine hours information are displayed in a common electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located below the tachometer in the lower right area of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The odometer, trip odometer, and engine hours information are not displayed simultaneously. The trip odometer reset switch on the instrument cluster circuit board toggles the display between odometer and trip odometer modes by depressing the odometer/trip odometer switch button that extends through the lower edge of the cluster lens, just left of the minor gauge set. When the trip odometer information is displayed, the word TRIP is also illuminated in the lower right corner of the odometer/trip odometer VFD in a blue-green color and at the same lighting level as the trip odometer information. The engine hours information replaces the selected odometer or trip odometer information whenever the ignition switch is in the ON position and the engine is not running. The odometer, trip odometer, and engine hours information is stored in the instrument cluster memory. This information can be increased when the proper inputs are provided to the instrument cluster, but the information cannot be decreased. The odometer can display values up to 999,999 kilometers (999,999 miles). The odometer latches at these values, and will not roll over to zero. The trip odometer can display values up to 999.9 kilometers (999.9 miles) before it rolls over to zero. Engine hours are displayed in the format, hr9999. The cluster will accumulate values up to 9,999 hours before the display rolls over to zero. The odometer display does not have a decimal point and will not show values less than a full unit (kilometer or mile), while the trip odometer display does have a decimal point and will show tenths of a unit (kilometer or mile). The unit of measure (kilometers or miles) for the odometer and trip odometer display is not shown in the VFD. The unit of measure for the instrument cluster odometer/trip odometer is selected at the time that it is manufactured, and cannot be changed. The odometer also has a RENTAL CAR mode, which will illuminate the odometer information in the VFD whenever the driver side front door is opened with the ignition switch in the OFF or ACCESSORY positions. During daylight hours (exterior lamps are OFF) the odometer VFD is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the VFD lighting level is adjusted with the other cluster general illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a PARADE mode position of the panel lamps dimmer thumbwheel allows the VFD to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The odometer/trip odometer VFD, the trip odometer switch, and the trip odometer switch button are serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Odometer - Description > Page 9827 Odometer: Description and Operation Odometer - Operation OPERATION The odometer and trip odometer give an indication to the vehicle operator of the distance the vehicle has traveled. The engine hours give an indication of the cumulative engine-on time. This indicator is controlled by the instrument cluster circuitry based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The odometer, trip odometer and engine hours information is displayed by the instrument cluster odometer/trip odometer Vacuum Fluorescent Display (VFD). The VFD displays the odometer information whenever any door is opened with the ignition switch in the OFF or ACCESSORY positions, and displays the last previously selected odometer or trip odometer information when the ignition switch turns to the ON or START positions. The instrument cluster circuitry controls the VFD and provides the following features: - Odometer/Trip Odometer Display Toggling - Actuating the trip odometer reset switch button momentarily with the VFD illuminated toggles the display between the odometer and trip odometer information. Each time the VFD is illuminated with the ignition switch in the ON or START positions, the display automatically returns to the last mode previously selected (odometer or trip odometer). - Engine Hours Display Toggling - When the trip odometer reset switch button is pressed and held for longer than about six seconds with the ignition switch in the ON position and the engine speed message from the PCM is zero, the trip odometer information momentarily displays, then the engine hours information displays. The VFD must display the odometer information when the trip odometer reset switch button is pressed in order to toggle to the engine hours display. The engine hours remains displayed for about 30 seconds, until the engine speed message is greater than zero, or until the ignition switch turns to the OFF position, whichever occurs first. - Trip Odometer Reset - When the trip odometer reset switch button is pressed and held for longer than about two seconds with the ignition switch in the ON or START positions, the trip odometer resets to 0.0 kilometers (miles). The VFD must display the trip odometer information in order for the trip odometer information to be reset. - GASCAP Message Display - On vehicles manufactured with a United States country code, each time the cluster receives an electronic message from the PCM indicating a monitored leak in the evaporative emissions system, the cluster replaces the displayed odometer/trip odometer value with the textual message, GASCAP. This message serves as a reminder to the vehicle operator to check that the gas cap is properly installed and tightened, but could also indicate another source of air leakage in the on-board evaporative and vapor recovery emissions systems. Unless the leak is corrected, this message latches and remains displayed during the current and each subsequent ignition cycle until the trip odometer reset button is pressed and released momentarily, which reverts the display to the odometer/trip odometer information that was last displayed for the remainder of that ignition cycle. Once the source of a leak has been corrected, either momentarily pressing the trip odometer reset button or cycling the ignition switch unlatches the message and return the odometer/trip odometer to normal operation. - NO-FUSE Message Display - Each time the cluster receives an electronic message from the Front Control Module (FCM) indicating the Ignition-Off Draw (IOD) feed for the cluster is an open circuit, the cluster replaces the displayed odometer/trip odometer value with the textual message, NO-FUSE. This message indicates that the IOD fuse is missing, blown or that the IOD feed circuit is ineffective. Unless the problem is corrected, this message latches and remains displayed during the current and each subsequent ignition cycle until the trip odometer reset button is pressed and released momentarily, which reverts the display to the odometer/trip odometer information that was last displayed for the remainder of that ignition cycle. Once the problem has been corrected, either momentarily pressing the trip odometer reset button or cycling the ignition switch unlatches the message and return the odometer/trip odometer to normal operation. - Ambient Temperature Display - On vehicles that are not equipped with the optional Electronic Vehicle Information Center (EVIC), each time the cluster receives an electronic ambient temperature message from the FCM, the cluster replaces the displayed odometer/trip odometer value with the ambient temperature value. This value displays and updates during the current ignition cycle until the trip odometer reset button is pressed and released momentarily, which reverts the display to the odometer/trip odometer information that was last displayed for the remainder of that ignition cycle. - Communication Error - If the cluster fails to receive an electronic distance message during normal operation, it holds and displays the last data received until the ignition switch is turned to the OFF position. If the cluster does not receive a distance message within one second after the ignition switch turns to the ON position, it displays the last distance value stored in the cluster memory. If the cluster is unable to display distance information due to an error internal to the cluster, the VFD displays Error. - Self Test - Each time the cluster is put through the self test, the odometer VFD displays all of its segments simultaneously, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The PCM continually monitors the vehicle speed pulse information received from the Vehicle Speed Sensor (VSS) and engine speed pulse information received from the crankshaft position sensor, then sends the proper messages to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the odometer/trip odometer or the instrument cluster circuitry that controls these functions, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the VSS, the crankshaft position sensor, the PCM, the CCN, the CAN data bus or the electronic communication related to odometer/trip odometer operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup Oil Change Reminder Lamp: Technical Service Bulletins Instruments - Vehicle Information Center Setup NUMBER: 08-002-09 GROUP: Electrical DATE: February 4, 2009 THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-014-07, DATED JULY 11, 2007, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES ADDITIONAL YEARS AND MODELS. SUBJECT: Electronic Vehicle Information Center (EVIC) Oil Change Indicator System - Dealer Preferences During Prep MODELS: 2008 (DR) Ram Truck **2009 (HB) Durango** **2009 (HG) Aspen** **2009 (JC) Journey** **2008 - 2009 (KA) Nitro** **2008 - 2009 (KK) Liberty** **2009 (LC) Challenger** **2008 - 2009 (LX) 300 / Magnum / Charger** **2008 - 2009 (RI) Caravan / Town & Country** NOTE: This Bulletin applies to vehicles equipped with a programmable EVIC. DISCUSSION: **Many models now include an oil change indicator system**. This system displays an "Oil Change Required" or "Oil Change" message at appropriate intervals on the instrument cluster. The vehicles listed above may be equipped with a programmable display on the Electronic Vehicle Information Center, (EVIC). The "Oil Change Required message may also include the dealerships name and phone number which can be programmed into the vehicle with the StarSCAN(R) or StarMOBILE(R) scan tool. NOTE: **Other vehicles may be added at any time. Dealers can determine if the feature is available by following the procedures below. If Enable/Disable Dealer Contact Information is active, the feature can be used to enter the servicing dealer's information.** The following procedure describes the steps to add, delete or change a dealership name and phone number on the display. NOTE: If NOT programmed during vehicle prep, customer approval MUST be obtained before adding or changing this information. NOTE: When performing this Procedure, the software release level in the StarSCAN(R) or StarMOBILE(R); must be programmed with the latest level software. The software release level is visible in the blue header at the top of the StarSCAN(R) or StarMOBILE(R) screen. 1. Connect the StarSCAN(R) or StarMOBILE(R). (in Pass-Through Mode) NOTE: To use the StarMOBILE(R) in Pass-Through Mode requires that StarMOBILE(R) be connected to the dealership network via a wired or wireless connection. For more information on how to use the StarMOBILE(R) in Pass-Through Mode, see the StarMOBILE(R) training tutorials available on DealerCONNECT > Service > Repair > StarSCAN(R) and StarMOBILE(R) Tools link or at the website. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Instruments - Vehicle Information Center Setup > Page 9832 2. From the Home Screen, enter "ECU VIEW or "VEHICLE PREP". 3. Select "CCN". 4. Select "Misc. Functions". 5. Select "Enable/Disable Dealer Contact Information". 6. Select "Enable" or "Disable" as desired. 7. If enabled, select "Program Dealer Contact Information" and follow on screen prompts. 8. "Reset will cause display to read: "Contact Dealer" as default. 9. Select finish to exit. POLICY: Information Only Disclaimer: This bulletin is supplied as technical information only and is not an authorization for repair. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Page 9833 Oil Change Reminder Lamp: Service and Repair Evic Equipped Vehicles Your vehicle is equipped with an engine oil change indicator system. The Oil Change Required message will flash in the EVIC display for approximately 10 seconds after a single chime has sounded to indicate the next scheduled oil change interval. The engine oil change indicator system is duty cycle based, which means the engine oil change interval may fluctuate dependent upon your personal driving style. Unless reset, this message will continue to display each time you turn the ignition switch to the ON/RUN position. To turn off the message temporarily, press and release the Menu button. To reset the oil change indicator system (after performing the scheduled maintenance) perform the following procedure: - Turn the ignition switch to the ON position (Do not start the engine). - Fully depress the accelerator pedal slowly three times within 10 seconds. - Turn the ignition switch to the OFF/LOCK position. NOTE: If the indicator message illuminates when you start the vehicle, the oil change indicator system did not reset. If necessary repeat this procedure. Non-Evic Equipped Vehicles Your vehicle is equipped with an engine oil change indicator system. The Change Oil message will flash in the instrument cluster odometer for approximately 12 seconds after a single chime has sounded to indicate the next scheduled oil change interval. The engine oil change indicator system is duty cycle based, which means the engine oil change interval may fluctuate dependent upon your personal driving style. Unless reset, this message will continue to display each time you turn the ignition switch to the ON/RUN position. To turn off the message temporarily, press and release the Trip Odometer button on the instrument cluster. To reset the oil change indicator system (after performing the scheduled maintenance) perform the following procedure: - Turn the ignition switch to the ON position (Do not start the engine). - Fully depress the accelerator pedal slowly three times within 10 seconds. - Turn the ignition switch to the OFF/LOCK position. NOTE: If the indicator message illuminates when you start the vehicle, the oil change indicator system did not reset. If necessary repeat this procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 9837 Oil Pressure Sender: Diagrams Connector - (ENGINE) 2 WAY SWITCH-OIL PRESSURE - (ENGINE) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Low Oil Pressure Indicator - Description Oil Pressure Warning Lamp/Indicator: Description and Operation Low Oil Pressure Indicator Description DESCRIPTION A low oil pressure indicator is standard equipment on all instrument clusters. This indicator is located near the upper edge of the instrument cluster, between the tachometer and the speedometer. The low oil pressure indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine Oil in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the icon to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The low oil pressure indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Low Oil Pressure Indicator - Description > Page 9842 Oil Pressure Warning Lamp/Indicator: Description and Operation Low Oil Pressure Indicator Operation OPERATION The low oil pressure indicator gives an indication to the vehicle operator when the engine oil pressure reading reflects a condition requiring immediate attention. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The low oil pressure indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the low oil pressure indicator for the following reasons: - Engine Oil Pressure Low Message - Each time the cluster receives an electronic engine oil pressure message from the PCM indicating the pressure is about 6.9 kPa (1 psi) or lower, the low oil pressure indicator illuminates. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the pressure is above about 6.9 kPa (1 psi), or until the ignition switch turns to the OFF position, whichever occurs first. The cluster only turns the indicator on in response to low engine oil pressure if the engine speed is greater than zero. - Self Test - Each time the cluster is put through the self test, the low oil pressure indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the engine oil pressure sensor to determine the engine oil pressure. The PCM then sends the proper messages to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the low oil pressure indicator or the instrument cluster circuitry that controls the LED, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the engine oil pressure sensor, the PCM, the CCN, the CAN data bus or the electronic communication related to low oil pressure indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor Description Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Description DESCRIPTION The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams refer to Wiring. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor Description > Page 9848 Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the A/C-heater control. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the A/C-heater control. Based upon the resistance in the sensor, the A/C-heater control senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Description and Operation > Page 9849 Outside Temperature Display Sensor: Testing and Inspection AMBIENT TEMPERATURE SENSOR The temperature function is supported by the ambient temperature sensor, a wiring circuit, the Controller Area Network (CAN) data bus circuit and the Integrated Power Module (IPM). When the sensor is exposed to temperatures above 55° C (131° F), or if the sensor circuit is shorted, 60° C (130/140° F) will appear in the Electronic Vehicle Information Center (EVIC) display in place of the temperature. When the sensor is exposed to temperatures below -40° C (-40° F) or if the sensor circuit is open, - - ° C (- - ° F) will be displayed on the EVIC. The ambient temperature sensor and circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, further testing of the CAN data bus, IPM and base EVIC system is necessary. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilo ohms. At 55° C (130° F), the sensor resistance is 2.488 kilo ohms. The sensor resistance should read between these two values. If OK, perform further diagnosis of the Electronic Vehicle Information Center (EVIC) system, See: Driver/Vehicle Information Display/Testing and Inspection. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Turn the ignition switch to the Off position. Disconnect the wire harness connector from the ambient temperature sensor. NOTE: Temperature readings do not update immediately. Allow up to 60 seconds after the ignition switch is turned to the On position for readings to meet test specifications. 2. Turn the ignition switch to the On position. The EVIC display should now read - - ° C (- - ° F). If OK, go to 3. If not OK, repair the shorted sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 3. Turn the ignition switch to the Off position. Taking care not to damage the wire terminals, connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. Turn the ignition switch to the On position. The EVIC display should now read 60 ° C (130/140° F). If OK, go to 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. NOTE: If the EVIC display does not show the ambient temperature in step 4, the vehicle may need to be driven several miles at a speed greater than 32 km/h (20 mph) for the temperature to update. 4. Turn the ignition switch to the Off position. Remove the jumper wire. Turn the ignition switch to the On position and wait until the EVIC display again reads - - ° C (- - ° F). Turn the ignition switch to the Off position. Reconnect the ambient temperature sensor. Turn the ignition switch to the On position. The EVIC display should now read the ambient temperature. If OK, the problem is intermittent. Perform further diagnosis while manipulating the related wire harnesses and components. If not OK, go to 5 5. Clear any Diagnostic Trouble Codes that may have been set while performing the test. Perform further diagnosis of the CAN data bus circuit, the IPM and the ambient temperature sensor (refer to the SENSOR TEST). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor - Removal Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Locate the ambient temperature sensor (1), on the right side of the radiator yoke (2) behind the grille. 3. Disconnect the wire harness connector (3) from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the radiator yoke. 5. Remove the ambient temperature sensor from the radiator yoke. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor - Removal > Page 9852 Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor Installation INSTALLATION 1. Position the ambient temperature sensor (1) onto the radiator yoke (2). 2. Install the screw that secures the ambient temperature sensor to the radiator yoke. Tighten the screw to 5.6 Nm (50 in. lbs.). 3. Connect the wire harness connector (3) to the ambient temperature sensor (1). 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation > Tow/Haul Indicator - Description Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator - Description DESCRIPTION A tow/haul indicator is standard equipment on all instrument clusters. The tow/haul indicator is located below the minor gauge set on the left side of the cluster. The tow/haul indicator consists of a stencil-like cutout of the text TOW/HAUL in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. When the exterior lighting is turned ON, the illumination intensity of the tow/haul indicator is dimmable, which is adjusted along with the cluster general illumination lighting using the panel lamps dimmer thumbwheel on the headlamp switch. The tow/haul indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component Information > Description and Operation > Tow/Haul Indicator - Description > Page 9857 Overdrive Indicator Lamp: Description and Operation Tow/Haul Indicator - Operation OPERATION The tow/haul indicator gives an indication to the vehicle operator when the tow/haul function switch has been selected, revising the shift schedule of the electronically controlled automatic transmission. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tow/haul indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the tow/haul indicator for the following reasons: - Tow/Haul Indicator Lamp-On Message - Each time the cluster receives an electronic tow/haul indicator lamp-on message from the PCM indicating that the tow/haul shift schedule has been selected, the indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the PCM, or until the ignition switch is turned to the OFF position, whichever occurs first. - self Test - Each time the cluster is put through the self test, the tow/haul indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the tow/haul switch to determine the proper outputs to the automatic transmission. The PCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the tow/haul indicator or the instrument cluster circuitry that controls the LED, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the transmission control system, the PCM, the CCN, the CAN data bus or the electronic communication related to tow/haul indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Description and Operation > Chime/Buzzer - Description Parking Assist Warning Indicator: Description and Operation Chime/Buzzer - Description PARK ASSIST SYSTEM A park assist system is an optional factory-installed electronic parking aid. During parking and other similar vehicle maneuvers this system alerts the vehicle operator to obstacles located in the path immediately behind the vehicle which, due to the surrounding rear vehicle structure, might be otherwise difficult to perceive. When an object is detected, the system uses an electromechanical transducer and Light Emitting Diode (LED) indicators within the park assist display unit to provide the vehicle operator with visual and audible indications of the presence and proximity of such objects. The park assist system includes the following major components, which are described in further detail elsewhere in this service information: - Electronic Vehicle Information Center (1) - In vehicles equipped with the optional park assist system, the Electronic Vehicle Information Center (EVIC) in the overhead console displays textual warnings and error messages and emits audible warnings related to the current operating status of the park assist system and provides an interface that allows the vehicle operator to manually disable or enable the system using the customer programmable features option. - Park Assist Display (3) - Vehicles equipped with the park assist system have a park assist display unit mounted in the rear of the headliner just forward of the liftgate opening. The body of the display is concealed above the headliner where it is secured by a retainer on the back of the headliner substrate. Only the narrow, oval-shaped smoked clear lens of the display is visible on the outer surface of the headliner. - Park Assist Module (2) - Vehicles equipped with the park assist system include a park assist module which is secured through integral mounting tabs by push-in type fasteners to the quarter inner panel above the left rear wheel housing where it is concealed beneath the quarter inner trim panel. - Park Assist Sensors (4) - Vehicles equipped with the park assist system have four ultrasonic park assist sensors that are concealed behind the rear bumper fascia. Each sensor is snapped into an individual molded plastic mounting bracket located at horizontal intervals along the back side of the rear bumper fascia. Hard wired circuitry connects the various park assist system components to each other through the electrical system of the vehicle. These hard wired circuits are integral to several wire harnesses, which are routed throughout the vehicle and retained by many different methods. These circuits may be connected to each other and to the vehicle electrical system through the use of a combination of soldered splices, splice block connectors, and many different types of wire harness terminal connectors and insulators. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, further details on wire harness routing and retention, as well as pin-out and location views for the various wire harness connectors, splices and grounds. The park assist system components cannot be adjusted or repaired. If any of the park assist system components is damaged or ineffective, that component must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Description and Operation > Chime/Buzzer - Description > Page 9862 Parking Assist Warning Indicator: Description and Operation Chime/Buzzer - Operation PARK ASSIST SYSTEM The park assist system is active only when the ignition switch is in the ON or START positions, the parking brake is released, the transmission gear selector lever is in either the REVERSE position and the vehicle speed is less than 16 kph (10 mph) or, the DRIVE position and the vehicle speed is less than 14 kph (8 mph) on deceleration, or 18 kph (12 mph) on acceleration. In vehicles equipped with this option, the system is enabled from the factory as a default. The system can be manually disabled and enabled by the vehicle operator using the customer programmable features option of the Electronic Vehicle Information Center (EVIC) in the overhead console. Reasons for disabling the system include trailer towing and off road use. With a trailer attached to the vehicle the audible and visible park assist alerts would be incessant whenever the gear selector lever was in the REVERSE position due to the proximity of the trailer to the rear of the vehicle. Similarly, operating the vehicle off road may cause the park assist alerts to become distracting due to the proximity of large trees or boulders and the extreme rear approach angles that may be encountered while maneuvering on off road trails or terrain. When the system is disabled, a PARK ASSIST DISABLED textual message will appear in the EVIC display whenever the gear selector lever is in the REVERSE position. The microprocessor based park assist module is the central component of the park assist system. It supplies voltage to the park assist sensors and the park assist display, receives and analyzes data from the sensors, calculates and communicates the proper display information to the park assist display, performs system diagnostics, and communicates with other electronic modules in the vehicle or with a diagnostic scan tool over the Controller Area Network (CAN) data bus. The module operates on battery voltage received through a fuse in the Junction Block (JB), and is grounded through a take out and eyelet terminal of the body wire harness that is secured by a screw to the left inner D-pillar. Four ultrasonic park assist sensors in the rear bumper fascia allow the park assist system to locate and identify the proximity of nearby obstacles. These sensors each generate ultrasonic sound pulses when triggered by the park assist module, then signal the module when an echo of the reflected sound pulses is received. The detection distance range from the rear of the vehicle is about 0.3 meters (11.8 inches) to about 2.0 meters (80 inches), and the detection height range from the ground is about 0.2 meters (7.8 inches) to about 0.8 meters (31 inches). The detection area extends somewhat around both rear sides (corners) of the vehicle. The park assist display unit provides the vehicle operator with both visible and audible warnings indicating the relative range of a detected object. The display is visible to the vehicle operator over an inboard shoulder when looking rearward while backing the vehicle up, but is not visible in a properly adjusted inside rear view mirror when looking forward. The display contains two sets of eight Light Emitting Diode (LED) indicator units, one set dedicated to each side of the vehicle, and an audible chime tone transducer. The LED units are concealed beneath a smoked oval lens and are not clearly visible when they are not illuminated. When the park assist system is active and no obstacles are detected (stand-by mode), the two rectangular amber LED units in the display are illuminated at a reduced intensity to provide visual confirmation that the system is operating. The display provides a visual indication of a detected object and its proximity by illuminating one or more LED indicators, beginning with the outer most round amber indicators and moving toward the center of the display as the vehicle gets closer to the object. As the vehicle comes to within about 200 centimeters (about 78.7 inches) of the object, one or both of the inner most rectangular amber LED indicators illuminate at full intensity and the display emits a single half-second audible beep. As the vehicle comes to within about 50 centimeters (19.7 inches) of the object, all of the amber indicators and the first red LED indicator are illuminated and the display emits a series of short, intermittent, audible beeps. If the audio system is turned ON, the audio output will be muted automatically while the park assist audible warning is being generated. The audible warning changes from intermittent beeps to a continuous tone as the final red indicator is illuminated and the vehicle comes to within 30 centimeters (11.8 inches) of a detected object. When the park assist module monitors a problem in any of the park assist system circuits or components, it stores a fault code or Diagnostic Trouble Code (DTC) in its memory circuit, illuminates all four red LED units in the park assist display, sends an electronic message to the EVIC, and a SERVICE PARK ASSIST SYSTEM textual message is displayed in the EVIC display. The hard wired circuits between components related to the park assist system may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the park assist system or the electronic controls or communication between modules and other devices that provide some features of the park assist system. The most reliable, efficient, and accurate means to diagnose the park assist system or the electronic controls and communication related to park assist system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Description and Operation > Chime/Buzzer - Description > Page 9863 Parking Assist Warning Indicator: Description and Operation Park Assist Display - Description DESCRIPTION The park assist display (1) is located in the headliner at the rear of the vehicle, just forward of the upper liftgate opening header. Only the smoked clear plastic display lens (3) is visible on the headliner. The lens prevents the 4 red Light Emitting Diode (LED) units and 12 amber LED units from being clearly visible unless they are illuminated by the electronic circuitry of the display. The remainder of the display including the mounting provisions and the electrical connection are concealed above the headliner. A molded plastic housing with an integral connector receptacle (2) at one end contains and protects the electronic circuitry of the display, including an audible tone transducer and an electronic communication chip. A molded plastic retainer (1) with three integral tabs (2) engages three slots integral to the display housing above the lens. The retainer is installed over the display housing above the headliner substrate to engage and securely lock the display into the opening in the headliner. An arrow and the text REAR are molded into an integral installation tab (3) to ensure correct retainer orientation. The park assist display is serviced only as a complete unit. It cannot be adjusted or repaired. If ineffective or damaged, the entire display unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Description and Operation > Chime/Buzzer - Description > Page 9864 Parking Assist Warning Indicator: Description and Operation Park Assist Display - Operation OPERATION The park assist display provides the vehicle operator with visual feedback by illuminating amber or red Light Emitting Diode (LED) units individually or in unison, and audible feedback by energizing an audible tone transducer on the display electronic circuit board to emit either an intermittent or a continuous tone. While the park assist system is active, the number, position and color of the illuminated LED units as well as the audible signal frequency indicate the relative position and distance of obstacles detected at the rear of the vehicle. The park assist display receives battery current and ground from and is completely controlled by the park assist module. The display also contains an electronic communication chip that allows bi-directional communication to occur with the park assist module over a dedicated serial bus line. The microprocessor in the park assist module completely controls the display outputs, continually monitors the display status, and will store a Diagnostic Trouble Code (DTC) in memory for any monitored fault it detects in the park assist display. The illumination intensity of the LED units is also controlled by the park assist module based upon internal programming and electronic panel lamps dimming messages received over the Controller Area Network (CAN) data bus. When the ignition switch is turned to the ON position, all 16 of the LED units in the display will illuminate in unison for approximately 1 second as a bulb test. This output will be interrupted if the system is active and senses an obstacle. Following the conclusion of the bulb test, when the system is active but no obstacle is detected, the display will indicate system readiness by illuminating the two inner most amber LED units (1) at a reduced intensity. As an obstacle is detected, the outermost amber LED unit (5) on the side of the vehicle where the obstacle was detected will be illuminated at normal intensity and a single short audible tone (one-half second duration) is sounded. Then additional amber LED units (6) will begin illuminating inward (2 or 4) as the obstacle gets closer until, finally, the two red LED units (7) are illuminated. When the final red LED unit (3) is illuminated, the obstacle is approximately 40 centimeters (16 inches) from the rear corner of the vehicle or approximately 50 centimeters (19.7 inches) from the rear bumper face and an intermittent audible tone will be generated. The frequency of the audible tone will increase as the obstacle continues to become closer until the tone is continuous when the obstacle is about 15 centimeters (6 inches) from the rear corner of the vehicle or about 30 centimeters (11.8 inches) from the rear bumper face. Whenever a park assist audible tone is being generated, the park assist module sends electronic messages to the radio over the CAN data bus to mute the audio system. The audible tone will be cancelled after about two seconds if the detected distance to the obstacle remains constant. See the Park Assist Display Outputs table for additional details. The hard wired circuits between components related to the park assist display may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the park assist display or the electronic controls or communication between modules and other devices that provide some features of the park assist system. The most reliable, efficient, and accurate means to diagnose the park assist display or the electronic controls and communication related to park assist display operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Description and Operation > Chime/Buzzer - Description > Page 9865 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Description and Operation > Page 9866 Parking Assist Warning Indicator: Testing and Inspection PARK ASSIST SYSTEM WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. If a SERVICE PARK ASSIST SYSTEM textual message appears in the Electronic Vehicle Information Center (EVIC) display, be certain to confirm the following: - Be certain that the rear bumper is free of dirt and debris to keep the system operating properly. - Be certain that the parking brake is not applied. - The presence of jackhammers, large trucks, and other vibrations in the vicinity of the vehicle could impact the performance of the system. The hard wired circuits between components related to the park assist system may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the park assist system or the electronic controls or communication between modules and other devices that provide some features of the park assist system. The most reliable, efficient, and accurate means to diagnose the park assist system or the electronic controls and communication related to park assist system operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Service and Repair > Park Assist Display - Removal Parking Assist Warning Indicator: Service and Repair Park Assist Display - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the trim from the upper liftgate opening. See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal. 3. Remove the trim from both upper D-pillars. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Removal. 4. Carefully pull down the rear edge of the headliner (5) from the upper liftgate opening header (2) far enough to access the rear park assist display housing (3) and the display retainer (4). 5. Disconnect the wire harness connector (1) from the connector receptacle on the left end of the display housing. 6. Carefully spread the front and rear edges of the molded plastic retainer far enough to disengage the three retainer tabs from the slots in the display housing, then lift the retainer off of the display housing. 7. Push the right end of the display out through the lower surface of the headliner, then slide the display toward the right side of the vehicle far enough to disengage the connector receptacle from the headliner opening. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator > Component Information > Service and Repair > Park Assist Display - Removal > Page 9869 Parking Assist Warning Indicator: Service and Repair Park Assist Display - Installation INSTALLATION 1. Carefully position the connector receptacle on the left end of the park assist display housing (3) through the left end of the display opening in the lower surface of the headliner (5). 2. Slide the display toward the left side of the vehicle far enough to engage the right end of the display housing into the right end of the display opening in the headliner. 3. Carefully pull down the rear edge of the headliner from the upper liftgate opening header (2) far enough to access the rear park assist display housing. 4. With the display lens held flush against the lower surface of the headliner, position the molded plastic retainer (4) over the display housing with the installation tab oriented towards the rear of the vehicle. 5. Slide the retainer down over the display housing until it is flash with the headliner substrate and the three tabs of the retainer are engaged in the three slots of the display housing. 6. Reconnect the wire harness connector (1) to the connector receptacle on the left end of the display housing. 7. Reinstall the trim onto both upper D-pillars. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Pillar Trim/D-Pillar Trim/Installation. 8. Reinstall the trim onto the upper liftgate opening. See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal. 9. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Description and Operation > Brake/Parking Brake Indicator - Description Parking Brake Warning Lamp: Description and Operation Brake/Parking Brake Indicator Description DESCRIPTION A brake indicator is standard equipment on all instrument clusters. This indicator is located in the center of the speedometer, in the area below and right of the speedometer needle hub. The brake indicator consists of a stencil-like cutout of the word BRAKE (all clusters with a miles-per-hour primary speedometer scale), or the International Control and Display Symbol icon for Brake Failure (all clusters with a kilometers-per-hour primary scale) in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The brake indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Description and Operation > Brake/Parking Brake Indicator - Description > Page 9874 Parking Brake Warning Lamp: Description and Operation Brake/Parking Brake Indicator Operation OPERATION The brake indicator gives an indication to the vehicle operator when the parking brake is applied, when there are certain brake hydraulic system malfunctions as indicated by a low brake hydraulic fluid level condition, or when the brake fluid level switch is disconnected. The brake indicator can also give an indication when certain faults are detected in the Antilock Brake System (ABS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming, electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus, and a hard wired input from the park brake switch. The brake indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the brake indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the ON position the brake indicator illuminates for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - Brake Indicator Lamp-On Message - Each time the cluster receives an electronic brake indicator lamp-on message from the CAB, the brake indicator illuminates. The CAB may also send lamp-on messages as feedback during ABS diagnostic procedures. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Park Brake Switch Input - Each time the cluster detects ground on the park brake switch sense circuit (park brake switch closed = park brake applied or not fully released) while the ignition switch is in the ON position, the brake indicator flashes on and off. The indicator continues to flash until the park brake switch sense input to the cluster is an open circuit (park brake switch open = park brake fully released), or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the instrument cluster is put through the self test, the brake indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The park brake switch on the park brake pedal mechanism provides a hardwired ground input to the instrument cluster circuitry through the park brake switch sense circuit whenever the park brake is applied or not fully released. The CAB continually monitors the ABS system circuits and sensors, including the brake fluid level switch on the brake master cylinder reservoir, to decide whether the system is in good operating condition. The CAB then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the CAB sends a lamp-on message after the bulb test, it indicates that the CAB has detected a brake hydraulic system malfunction or that the ABS system has become ineffective. The CAB stores a Diagnostic Trouble Code (DTC) for any malfunction it detects. For further diagnosis of the brake indicator or the instrument cluster circuitry that controls the LED, See: Instrument Cluster / Carrier/Testing and Inspection. Use conventional diagnostic tools and procedures for the hardwired park brake switch input to the instrument cluster. Refer to the appropriate wiring information. Use a diagnostic scan tool for proper diagnosis of the brake fluid level switch, the ABS, the CAB, the CCN, the CAN data bus or the electronic communication related to brake indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Lamp > Component Information > Description and Operation > Page 9875 Parking Brake Warning Lamp: Testing and Inspection BRAKE INDICATOR WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. The hardwired park brake switch input to the instrument cluster, also known as the Cab Compartment Node, (CCN) may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire harness and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the CCN, the Controller Antilock Brake (CAB), the Controller Area Network (CAN) data bus or the electronic message inputs also used by the CCN to provide brake indicator operation. The most reliable, efficient and accurate means to diagnose the CCN, the CAB, the CAN data bus or the electronic communication related to brake indicator operation, requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations > Page 9879 Parking Brake Warning Switch: Diagrams Connector - (BODY) 1 WAY SWITCH-PARKING BRAKE - (BODY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch - Description > Page 9882 Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Description and Operation > Page 9883 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. See: Brakes and Traction Control/Testing and Inspection . If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 9886 Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Seat Belt Warning Lamp - Description Seat Belt Reminder Lamp: Description and Operation Seat Belt Warning Lamp - Description DESCRIPTION A seatbelt indicator is standard equipment on all instrument clusters. This indicator is located near the upper edge of the instrument cluster, between the minor gauge set and the speedometer. The seatbelt indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Seat Belt in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The seatbelt indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Seat Belt Warning Lamp - Description > Page 9891 Seat Belt Reminder Lamp: Description and Operation Seat Belt Warning Lamp - Operation OPERATION The seatbelt indicator gives an indication to the vehicle operator of the status of the driver side front seatbelt. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hardwired input from the seatbelt switch in the driver side front seatbelt retractor through the seat belt indicator driver circuit. The seatbelt indicator also includes a programmable enhanced seatbelt reminder or beltminder feature that is enabled when the vehicle is shipped from the factory. This beltminder feature can be disabled and enabled by the customer using a specific programming event sequence, or by the dealer using a diagnostic scan tool. The seatbelt indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED will always be off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the seatbelt indicator for the following reasons: Seatbelt Reminder Function - Each time the cluster receives a battery current input on the fused ignition switch output (run-start) circuit, the indicator illuminates as a seatbelt reminder for about six seconds, or until the ignition switch turns to the OFF position, whichever occurs first. This reminder function occurs regardless of the status of the seatbelt switch input to the cluster. - Driver Side Front Seatbelt Not Buckled - Beltminder Active - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seat belt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the START or ON positions, the indicator illuminates. In addition, if the driver side front seatbelt remains unbuckled about 60 seconds after the conclusion of the seatbelt reminder function with the vehicle speed greater than about 8 kilometers-per-hour (5 miles-per-hour), the seatbelt indicator begins to cycle between flashing on and off for 3 seconds, then lighting solid for 2 seconds. The seatbelt indicator continues to cycle between flashing and solid illumination for 13 complete cycles, until the seatbelt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch turns to the OFF position, whichever occurs first. - Driver Side Front Seatbelt Not Buckled - Beltminder Inactive - Following the seatbelt reminder function, each time the cluster detects an open circuit on the seatbelt indicator driver circuit (seatbelt switch open = seatbelt unbuckled) with the ignition switch in the START or ON positions, the indicator illuminates. The seatbelt indicator remains illuminated until the seatbelt indicator driver input to the cluster is closed to ground (seatbelt switch closed = seatbelt buckled), or until the ignition switch turns to the OFF position, whichever occurs first. - Airbag Indicator Backup - If the instrument cluster detects a fault in the airbag indicator circuit it sends an electronic message indicating the fault to the Occupant Restraint Controller (ORC), then flash the seatbelt indicator on and off. The cluster continues to flash the indicator until the airbag indicator circuit fault is resolved, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the seatbelt indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The seatbelt switch is connected in series between ground and the seatbelt indicator driver input to the instrument cluster, also known as the Cab Compartment Node (CCN). Use conventional diagnostic tools and procedures to diagnose the hardwired seatbelt switch input to the instrument cluster. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Page 9892 Seat Belt Reminder Lamp: Testing and Inspection ENHANCED SEATBELT REMINDER PROGRAMMING The seatbelt indicator also includes a programmable enhanced seatbelt reminder or BELTMINDER feature that is enabled when the vehicle is shipped from the factory. This BELTMINDER feature provides extended and modified visual seatbelt indicator and audible chime warning responses to an unbuckled driver side front seat belt. The BELTMINDER feature may be disabled or enabled by the customer using the programming sequence that follows, or by the dealer using a diagnostic scan tool. CUSTOMER PROGRAMMING SEQUENCE NOTE: The following sequence of events must occur within 60 seconds of the ignition switch being placed in the ON position in order for the programming to be completed successfully. 1. With all doors closed and the ignition switch in any position except ON or START, buckle the driver side front seat belt. 2. Turn the ignition switch to the ON position and wait for the seatbelt indicator reminder function to conclude (about six seconds). 3. Unbuckle and buckle the driver side front seat belt three or more times, ending with the belt buckled. 4. Turn the ignition switch to any position except ON or START to toggle the BELTMINDER feature from its current setting (from active to inactive, or from inactive to active). A single chime tone will provide an audible confirmation that the programming sequence has been successfully completed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation > Door Ajar Switch - Description Door Switch: Description and Operation Door Ajar Switch - Description DOOR This vehicle has four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Latch/Service and Repair/Front Door Latch - Removal or See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Rear Door Latch - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Description and Operation > Door Ajar Switch - Description > Page 9898 Door Switch: Description and Operation Door Ajar Switch - Operation DOOR The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The rear door ajar switches are hard wired in series between a body ground and the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). On vehicles not equipped with the optional memory system, the front door ajar switches are also hard wired in series between ground and the EMIC. On vehicles equipped with the optional memory system each front door ajar switch is hard wired in series between ground and its respective driver or passenger Memory Mirror Module (MMM) located in the front door. The MMM then sends electronic door ajar switch status messages to the EMIC over the Controller Area Network (CAN) data bus. Both the EMIC and the MMM read the hard wired door ajar switch inputs through internal pull-ups, then use these inputs to control many electronic functions and features of the vehicle. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 9902 Fuel Gauge Sender: Diagrams Connector - (CHASSIS) 4 WAY MODULE-FUEL PUMP - (CHASSIS) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 9903 Fuel Gauge Sender: Description and Operation DESCRIPTION The fuel pump module assembly (4) is located on the top of the fuel tank (2). The module assembly (5) contains the following components: - An internal fuel filter - A separate fuel pick-up, or inlet filter (3) - A fuel pressure regulator (4) - An electric fuel pump (2) - A lock ring to retain pump module to tank - A soft gasket between tank flange and module - A fuel gauge sending unit (fuel level sensor) (1) - Fuel line connection (6) If the fuel gauge sending unit, electrical fuel pump, primary inlet filter, fuel filter or fuel pressure regulator require service, the fuel pump module must be replaced. Electric Fuel Pump The electric fuel pump is located inside of the fuel pump module. A 12 volt, permanent magnet, electric motor powers the fuel pump. The electric fuel pump is not a separate, serviceable component. Fuel Filters Two fuel filters are used. One is located at the bottom of the fuel pump module. The other is located inside the module. A separate frame mounted fuel filter is not used with any engine. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Locations > Page 9904 Both fuel filters are designed for extended service. They do not require normal scheduled maintenance. Filters should only be replaced if a diagnostic procedure indicates to do so. Fuel Pressure Regulator The fuel pressure regulator is located within fuel pump module. Fuel Gauge Sending Unit (Fuel level sensor) The fuel gauge sending unit (fuel level sensor) is attached to the side of the fuel pump module. The sending unit consists of a float, an arm, and a variable resistor track (card). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal Fuel Gauge Sender: Service and Repair Fuel Pump Module - Removal REMOVAL WARNING: The fuel system is under a constant pressure, even with the engine off. Before servicing the fuel pump module, the fuel system pressure must be released. 1. Perform the fuel system pressure release procedure See: Engine, Cooling and Exhaust/Engine/Cylinder Head Assembly/Fuel Pressure Release/Service and Repair 2. Disconnect and isolate the negative battery cable. 3. Drain and remove the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Removal 4. Note the rotational position of the module before attempting removal. An indexing arrow is located on top of the module for this purpose. 5. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 6. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 7. Rotate the breaker bar counterclockwise to remove the lock ring. 8. Remove the lock ring. The module will spring up slightly when the lock ring is removed. 9. Remove the module from the fuel tank. Be careful not to bend the float arm during removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Service and Repair > Fuel Pump Module - Removal > Page 9907 Fuel Gauge Sender: Service and Repair Fuel Pump Module - Installation INSTALLATION CAUTION: Whenever the fuel pump module is serviced, the rubber seal (gasket) must be replaced. 1. Using a new seal (gasket), position the fuel pump module into the opening of the fuel tank. 2. Rotate the module until the embossed alignment arrow points to the center alignment mark. This step must be performed to prevent the float from contacting the side of the fuel tank. Also be sure the fuel fitting on top of the pump module is pointed to the left side of the vehicle. 3. Position the lock ring (5) over the top of the fuel pump module. 4. Position the lock ring remover/installer 9340 (3) into the notches on the outside edge of the lock ring (5). 5. Install a 1/2 inch drive breaker bar (1) into the lock ring remover/installer 9340 (3). 6. Tighten the lock ring (clockwise) until all seven notches have engaged. 7. Install the fuel tank See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Tank/Service and Repair/Removal and Replacement/Fuel Tank - Installation 8. Lower the vehicle. 9. Connect the fuel line quick connect fitting to the fuel rail (1)See: Powertrain Management/Fuel Delivery and Air Induction/Fuel Line Coupler/Service and Repair 10. Connect the negative battery cable. 11. Install the fuel fill cap. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor - Description Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Description DESCRIPTION The ambient temperature sensor is a variable resistor mounted to a bracket that is secured with a screw to the right side of the radiator yoke, behind the radiator grille and in front of the engine compartment. For complete circuit diagrams refer to Wiring. The ambient temperature sensor cannot be adjusted or repaired and, if inoperative or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Ambient Temperature Sensor - Description > Page 9912 Outside Temperature Display Sensor: Description and Operation Ambient Temperature Sensor Operation OPERATION The ambient temperature sensor is a variable resistor that operates on a five-volt reference signal sent to it by the A/C-heater control. The resistance in the sensor changes as temperature changes, changing the temperature sensor signal circuit voltage to the A/C-heater control. Based upon the resistance in the sensor, the A/C-heater control senses a specific voltage on the temperature sensor signal circuit, which it is programmed to correspond to a specific temperature. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Description and Operation > Page 9913 Outside Temperature Display Sensor: Testing and Inspection AMBIENT TEMPERATURE SENSOR The temperature function is supported by the ambient temperature sensor, a wiring circuit, the Controller Area Network (CAN) data bus circuit and the Integrated Power Module (IPM). When the sensor is exposed to temperatures above 55° C (131° F), or if the sensor circuit is shorted, 60° C (130/140° F) will appear in the Electronic Vehicle Information Center (EVIC) display in place of the temperature. When the sensor is exposed to temperatures below -40° C (-40° F) or if the sensor circuit is open, - - ° C (- - ° F) will be displayed on the EVIC. The ambient temperature sensor and circuit can also be diagnosed using the following Sensor Test, and Sensor Circuit Test. If the temperature sensor and circuit are confirmed to be OK, but the temperature display is inoperative or incorrect, further testing of the CAN data bus, IPM and base EVIC system is necessary. SENSOR TEST 1. Turn the ignition switch to the Off position. Disconnect the ambient temperature sensor harness connector. 2. Measure the resistance of the ambient temperature sensor. At - 40° C (- 40° F), the sensor resistance is 336 kilo ohms. At 55° C (130° F), the sensor resistance is 2.488 kilo ohms. The sensor resistance should read between these two values. If OK, perform further diagnosis of the Electronic Vehicle Information Center (EVIC) system, See: Driver/Vehicle Information Display/Testing and Inspection. If not OK, replace the inoperative ambient temperature sensor. SENSOR CIRCUIT TEST For complete circuit diagrams, refer to the appropriate wiring information. The wiring information includes wiring diagrams, proper wire and connector repair procedures, details of wire harness routing and retention, connector pin-out information and location views for the various wire harness connectors, splices and grounds. 1. Turn the ignition switch to the Off position. Disconnect the wire harness connector from the ambient temperature sensor. NOTE: Temperature readings do not update immediately. Allow up to 60 seconds after the ignition switch is turned to the On position for readings to meet test specifications. 2. Turn the ignition switch to the On position. The EVIC display should now read - - ° C (- - ° F). If OK, go to 3. If not OK, repair the shorted sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. 3. Turn the ignition switch to the Off position. Taking care not to damage the wire terminals, connect a jumper wire between the two terminals in the body half of the ambient temperature sensor harness connector. Turn the ignition switch to the On position. The EVIC display should now read 60 ° C (130/140° F). If OK, go to 4. If not OK, repair the open sensor return circuit or ambient temperature sensor signal circuit to the ambient temperature sensor as required. NOTE: If the EVIC display does not show the ambient temperature in step 4, the vehicle may need to be driven several miles at a speed greater than 32 km/h (20 mph) for the temperature to update. 4. Turn the ignition switch to the Off position. Remove the jumper wire. Turn the ignition switch to the On position and wait until the EVIC display again reads - - ° C (- - ° F). Turn the ignition switch to the Off position. Reconnect the ambient temperature sensor. Turn the ignition switch to the On position. The EVIC display should now read the ambient temperature. If OK, the problem is intermittent. Perform further diagnosis while manipulating the related wire harnesses and components. If not OK, go to 5 5. Clear any Diagnostic Trouble Codes that may have been set while performing the test. Perform further diagnosis of the CAN data bus circuit, the IPM and the ambient temperature sensor (refer to the SENSOR TEST). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor Removal Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor - Removal REMOVAL 1. Disconnect and isolate the battery negative cable. 2. Locate the ambient temperature sensor (1), on the right side of the radiator yoke (2) behind the grille. 3. Disconnect the wire harness connector (3) from the ambient temperature sensor connector receptacle. 4. Remove the one screw that secures the ambient temperature sensor bracket to the radiator yoke. 5. Remove the ambient temperature sensor from the radiator yoke. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Outside Temperature Display Sensor > Component Information > Service and Repair > Ambient Temperature Sensor Removal > Page 9916 Outside Temperature Display Sensor: Service and Repair Ambient Temperature Sensor Installation INSTALLATION 1. Position the ambient temperature sensor (1) onto the radiator yoke (2). 2. Install the screw that secures the ambient temperature sensor to the radiator yoke. Tighten the screw to 5.6 Nm (50 in. lbs.). 3. Connect the wire harness connector (3) to the ambient temperature sensor (1). 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations > Page 9920 Parking Brake Warning Switch: Diagrams Connector - (BODY) 1 WAY SWITCH-PARKING BRAKE - (BODY) 1 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch Description Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Description DESCRIPTION The park brake switch (1) is located on the park brake lever mechanism on the cowl side inner panel below the instrument panel, to the left of the steering column. This switch includes a spade-type output terminal (3) that connects the switch to the vehicle electrical system through a dedicated take out and connector of the body wire harness. The output terminal is integral to the stationary contact within a molded plastic insulator. A locating tab on the insulator engages a slot in the park brake lever mechanism for positive switch location. External to the insulator is a movable leaf contact with an integral grounding lug (4) on one end and an integral actuating lever and follower (2) on the opposite end. The switch is secured to and grounded by a single screw to the park brake lever mechanism. The park brake switch cannot be adjusted or repaired and, if ineffective or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Parking Brake Switch Description > Page 9923 Parking Brake Warning Switch: Description and Operation Parking Brake Switch - Operation OPERATION The park brake switch is a normally closed, mechanically actuated leaf contact switch that is operated by the park brake lever mechanism. The switch is grounded through its mounting to the park brake lever mechanism and provides a ground input to the Electro Mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a park brake switch sense circuit whenever the park brake is applied, and opens this circuit whenever the park brake is released. The park brake switch sense input to the EMIC is used for control of the brake indicator and may also be used as a logic input for other electronic features in the vehicle. The park brake switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Description and Operation > Page 9924 Parking Brake Warning Switch: Testing and Inspection PARK BRAKE SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. NOTE: If the brake indicator stays ON with the ignition switch in the ON position and the park brake released, or comes ON while driving, the brake system must be diagnosed and repaired prior to performing the following tests. See: Brakes and Traction Control/Testing and Inspection . If no brake system problem is found, the following procedures will help to locate a shorted or open park brake switch sense circuit, or an ineffective park brake switch. INDICATOR ILLUMINATES DURING BULB TEST, BUT DOES NOT WHEN PARK BRAKE APPLIED 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Apply the parking brake. Check for continuity between the park brake switch terminal and a good ground. There should be continuity. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavities of the body wire harness connector for the park brake switch and the instrument panel wire harness connector for the instrument cluster. There should be continuity. If not OK, repair the open park brake switch sense circuit between the park brake switch and the instrument cluster as required. INDICATOR REMAINS ILLUMINATED - BRAKE SYSTEM CHECKS OKAY 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. Disconnect the body wire harness connector for the park brake switch from the switch terminal. Check for continuity between the terminal of the park brake switch and a good ground. There should be no continuity with the park brake released, and continuity with the park brake applied. If OK, go to 2. If not OK, replace the ineffective park brake switch. 2. Disconnect the instrument panel wire harness connector (Connector C1) for the instrument cluster from the cluster connector receptacle. Check for continuity between the park brake switch sense circuit cavity of the body wire harness connector for the park brake switch and a good ground. There should be no continuity. If not OK, repair the shorted park brake switch sense circuit between the park brake switch and the instrument cluster as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Apply the parking brake. 3. Reach under the left end of the instrument panel to access and disconnect the body wire harness connector (2) from the terminal of the park brake switch (4) located on the park brake lever mechanism (1) on the left cowl side inner panel. 4. Remove the screw (3) that secures the park brake switch to the park brake lever mechanism. 5. Remove the switch from the park brake lever mechanism. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair > Parking Brake Switch - Removal > Page 9927 Parking Brake Warning Switch: Service and Repair Parking Brake Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Reach under the left end of the instrument panel to position the park brake switch (4) onto the park brake lever mechanism (1) on the left cowl side inner panel. Be certain to engage the locating pin on the back of the switch insulator into the locating slot in the lever mechanism bracket. 2. Install and tighten the screw (3) that secures the park brake switch to the park brake lever mechanism. Tighten the screw to 3 Nm (24 in. lbs.). 3. Reconnect the body wire harness connector (2) to the terminal of the park brake switch. 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. 5. Turn the ignition switch to the ON position and check for proper brake indicator operation with the parking brake applied, then release the parking brake and check that the brake indicator extinguishes. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > Speedometer - Description Speedometer Head: Description and Operation Speedometer - Description DESCRIPTION A speedometer is standard equipment on all instrument clusters. The speedometer is located in the center of the instrument cluster, between the tachometer and the minor gauge set. The speedometer consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 210 degree primary scale on the gauge dial face that reads left-to-right either from 0 to 120 mph, or from 0 to 200 km/h, depending upon the market for which the vehicle is manufactured. Each version also has a secondary inner scale on the gauge dial face that provides the equivalent opposite units from the primary scale. Text appearing on the cluster overlay above the hub of the speedometer needle abbreviates the unit of measure for the primary scale (either MPH or km/h), followed by the unit of measure for the secondary scale. The speedometer graphics are black (primary scale) and blue (secondary scale) against a white field, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the white gauge dial face appears blue-green with the black and blue graphics silhouetted against the illuminated background and the red gauge needle still appears red. Gauge illumination is provided by an integral electro-luminescent lamp that is serviced as a unit with the instrument cluster. The speedometer is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > Speedometer - Description > Page 9932 Speedometer Head: Description and Operation Speedometer - Operation OPERATION The speedometer gives an indication to the vehicle operator of the vehicle road speed. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The speedometer is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch turns to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Vehicle Speed Message - Each time the cluster receives an electronic vehicle speed message from the PCM it calculates the correct vehicle speed reading and position the gauge needle at that relative speed position on the gauge scale. The cluster receives a new message and reposition the gauge pointer accordingly about every 88 milliseconds. The gauge needle continually positions at the relative vehicle speed position on the gauge scale until the vehicle stops moving, or until the ignition switch turns to the OFF position, whichever occurs first. - Communication Error - If the cluster fails to receive a speed message, it holds the gauge needle at the last indication for about three seconds, or until the ignition switch turns to the OFF position, whichever occurs first. After three seconds, the gauge needle returns to the left end of the gauge scale. - Self Test - Each time the cluster is put through the self test, the speedometer needle is swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the Vehicle Speed Sensor (VSS) to determine the vehicle road speed. The PCM then sends the proper vehicle speed messages to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the speedometer or the instrument cluster circuitry that controls the gauge, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the VSS, the PCM, the CCN, the CAN data bus or the electronic communication related to speedometer operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation > Tachometer - Description Tachometer: Description and Operation Tachometer - Description DESCRIPTION A tachometer is standard equipment on all instrument clusters. The tachometer is located to the right side of the instrument cluster, just right of the speedometer. The tachometer consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 210 degree scale on the gauge dial face that reads left-to-right from 0 to 7. The text RPM X 1000 imprinted on the cluster overlay directly above the hub of the tachometer needle identifies that each number on the tachometer scale is to be multiplied by 1000 rpm. The tachometer graphics are black against a white field, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the white gauge dial face appears blue-green with the black graphics silhouetted against the illuminated background and the red gauge needle still appears red. Gauge illumination is provided by an integral electro-luminescent lamp that is serviced as a unit with the instrument cluster. The tachometer is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation > Tachometer - Description > Page 9937 Tachometer: Description and Operation Tachometer - Operation OPERATION The tachometer gives an indication to the vehicle operator of the engine speed. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The tachometer is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch turns to the OFF position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Speed Message - Each time the cluster receives an electronic engine speed message from the PCM it calculates the correct engine speed reading and position the gauge needle at that relative speed position on the gauge scale. The cluster receives a new message and reposition the gauge pointer accordingly about every 88 milliseconds. The gauge needle continually repositions at the relative engine speed position on the gauge scale until the engine stops running, or until the ignition switch turns to the OFF position, whichever occurs first. - Communication Error - If the cluster fails to receive an engine speed message, it holds the gauge needle at the last indication for about three seconds, or until the ignition switch turns to the OFF position, whichever occurs first. After three seconds, the gauge needle return's to the left end of the gauge scale. - Self Test - Each time the cluster is put through the self test, the tachometer needle is swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the crankshaft position sensor to determine the engine speed. The PCM then sends the proper engine speed messages to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the tachometer or the instrument cluster circuitry that controls the gauge, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the crankshaft position sensor, the PCM, the CCN, the CAN data bus or the electronic communication related to tachometer operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Temperature Gauge - Description Temperature Gauge: Description and Operation Temperature Gauge - Description DESCRIPTION An engine coolant temperature gauge is standard equipment on all instrument clusters. This gauge is part of the minor gauge set with the fuel gauge located on the left side of the instrument cluster, just left of the speedometer. The gauge consists of a movable gauge needle or pointer controlled by the instrument cluster circuitry and a fixed 90 degree gauge scale on the cluster overlay that reads bottom-to-top from C (or Cold) to H (or Hot). An International Control and Display Symbol icon for Engine Coolant Temperature is located on the cluster overlay, directly below the bottom end of the scale. The engine coolant temperature gauge graphics are black against a white field except for a single red graduation at the high end of the gauge scale, making them clearly visible within the instrument cluster in daylight. When illuminated from behind by the panel lamps dimmer controlled cluster general illumination lighting with the exterior lamps turned ON, the white gauge dial face appears blue-green with the black graphics silhouetted against the illuminated background and the red graphics and the red gauge needle still appear red. Gauge illumination is provided by an integral electro-luminescent lamp that is serviced as a unit with the instrument cluster. The engine coolant temperature gauge is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Temperature Gauge - Description > Page 9942 Temperature Gauge: Description and Operation Temperature Gauge - Operation OPERATION The engine coolant temperature gauge gives an indication to the vehicle operator of the engine coolant temperature. This gauge is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The engine coolant temperature gauge is an air core magnetic unit that receives battery current on the instrument cluster electronic circuit board through the fused ignition switch output (run-start) circuit whenever the ignition switch is in the ON or START positions. The cluster is programmed to move the gauge needle back to the low end of the scale after the ignition switch is turned to the off position. The instrument cluster circuitry controls the gauge needle position and provides the following features: - Engine Temperature Message - Each time the cluster receives an electronic engine temperature message from the PCM indicating the temperature is between the low end of normal [about 54 °C (130 °F)] and the high end of normal [about 122 °C (252 °F)], the gauge needle moves to the actual relative temperature position on the gauge scale. - Engine Temperature Low Message - Each time the cluster receives an electronic engine temperature message from the PCM indicating the temperature is below the low end of normal [about 54 °C (130 °F)], the gauge needle is held at the C increment at the low end of the gauge scale. The gauge needle remains at the low end of the gauge scale until the cluster receives a message from the PCM indicating that the temperature is above about 54 °C (130 °F), or until the ignition switch turns to the OFF position, whichever occurs first. - Engine Temperature High Message - Each time the cluster receives an electronic engine temperature message from the PCM indicating the temperature is above about 122 °C (252 °F), the gauge needle moves to the red zone at the high end of the gauge scale, the engine temperature indicator illuminates and a single chime tone is sounded. The gauge needle remains in the red zone and the engine temperature indicator remains illuminated until the cluster receives a message from the PCM indicating that the temperature is below about 122 °C (252 °F), or until the ignition switch turns to the OFF position, whichever occurs first. The chime tone feature only repeats during the same ignition cycle if the engine temperature indicator is cycled off then on again by the appropriate messages from the PCM. - Communication Error - If the cluster fails to receive an engine temperature message, it holds the gauge needle at the last indication for about five seconds or until the ignition switch turns to the OFF position, whichever occurs first. After five seconds, the cluster moves the gauge needle to the low end of the gauge scale. - Self Test - Each time the cluster is put through the self test, the engine coolant temperature gauge needle is swept to several calibration points on the gauge scale in a prescribed sequence in order to confirm the functionality of the gauge and the cluster control circuitry. The PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM then sends the proper messages to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the engine coolant temperature gauge or the instrument cluster circuitry that controls the gauge, See: Instrument Cluster / Carrier/Testing and Inspection. If the instrument cluster turns on the engine temperature indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. Use a diagnostic scan tool for proper diagnosis of the engine coolant temperature sensor, the PCM, the CCN, the CAN data bus or the electronic communication related to engine coolant temperature gauge operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Engine Temperature Lamp - Description Temperature Warning Lamp/Indicator: Description and Operation Engine Temperature Lamp Description DESCRIPTION An engine temperature indicator is standard equipment on all instrument clusters. The engine temperature indicator is located near the upper edge of the instrument cluster, between the minor gauge set and the speedometer. The engine temperature indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Engine Coolant Temperature in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A red Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in red through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The engine temperature indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation > Engine Temperature Lamp - Description > Page 9947 Temperature Warning Lamp/Indicator: Description and Operation Engine Temperature Lamp Operation OPERATION The engine temperature indicator gives an indication to the vehicle operator when the engine temperature gauge reading reflects a condition requiring immediate attention. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The engine temperature indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the engine temperature indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the on position the engine temperature indicator illuminates for about two seconds as a bulb test. The entire bulb test is a function of the PCM. - Engine Temperature High Message - Each time the cluster receives an electronic engine temperature message from the PCM indicating the temperature is above about 122 °C (252 °F), the engine temperature indicator illuminates and a single chime tone is sounded. The indicator remains illuminated until the cluster receives a message from the PCM indicating that the temperature is below about 119 °C (246 °F), or until the ignition switch is turned to the off position, whichever occurs first. The chime tone feature only repeats during the same ignition cycle if the engine temperature indicator is cycled off, then on again by the appropriate messages from the PCM. - Self Test - Each time the cluster is put through the self test, the engine temperature indicator will be turned on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The PCM continually monitors the engine coolant temperature sensor to determine the engine operating temperature. The PCM then sends the proper messages to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the engine temperature indicator or the instrument cluster circuitry that controls the LED, See: Instrument Cluster / Carrier/Testing and Inspection. If the instrument cluster turns ON the engine temperature indicator due to a high engine temperature gauge reading, it may indicate that the engine or the engine cooling system requires service. Use a diagnostic scan tool for proper diagnosis of the engine coolant temperature sensor, the PCM, the CCN, the CAN data bus or the electronic communication related to engine temperature indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Indicator - Description Low Tire Pressure Indicator: Description and Operation Low Tire Pressure Indicator - Description DESCRIPTION A Tire Pressure Monitor (TPM) indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with the optional TPM, this indicator is electronically disabled. This indicator is located in the speedometer dial face to the left of the speedometer needle hub in the instrument cluster overlay. The TPM indicator consists of a stencil-like cutout of an icon that represents a cross-section of a tire with a centered exclamation point in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The TPM indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Low Tire Pressure Indicator > Component Information > Description and Operation > Low Tire Pressure Indicator - Description > Page 9953 Low Tire Pressure Indicator: Description and Operation Low Tire Pressure Indicator - Operation OPERATION The Tire Pressure Monitor (TPM) indicator gives an indication to the vehicle operator of the status of the TPM system. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Sentry Key REmote Entry Module (SKREEM), over the Controller Area Network (CAN) data bus. The TPM indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the TPM indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position, the SKREEM sends an electronic TPM indicator lamp-on message to the cluster to illuminate the TPM indicator for about three seconds as a bulb test. - TPM Indicator Lamp-On Message - Each time the cluster receives an electronic TPM indicator lamp-on message from the SKREEM, the TPM indicator illuminates. The indicator can be flashed on and off, or illuminated solid, as dictated by the SKREEM message. The indicator remains illuminated until the cluster receives a lamp-off message from the SKREEM or until the ignition switch is turned to the OFF position, whichever occurs first. - Communication Error - If the cluster receives no TPM lamp-on or lamp-off messages from the SKREEM for six consecutive seconds, the TPM indicator is illuminated by the instrument cluster. The indicator remains controlled and illuminated by the cluster until a valid lamp-on or lamp-off message is received from the SKREEM. - Self Test - Each time the cluster is put through the self test, the TPM indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The SKREEM performs a self-test each time the ignition switch is turned to the ON position to decide whether the TPM system is in good operating condition and whether the tire inflation pressures are too high or low. The SKREEM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). If the instrument cluster turns on the TPM indicator after the bulb test, it indicates that the inflation pressure of a tire is too low or that a malfunction has occurred and the TPM system is ineffective. Use a diagnostic scan tool for proper diagnosis of the TPM system, the SKREEM, the CCN, the CAN data bus or the electronic communication related to TPM indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 9958 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Locations > Left Front Tire Pressure Transponder > Page 9959 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way Tire Pressure Monitor Receiver / Transponder: Diagrams Left Front Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT FRONT - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way > Page 9962 Tire Pressure Monitor Receiver / Transponder: Diagrams Left Rear Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-LEFT REAR - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Diagrams > Left Front Tire Pressure Transponder (Chassis) 6 Way > Page 9963 Tire Pressure Monitor Receiver / Transponder: Diagrams Right Front Tire Pressure Transponder (Chassis) 6 Way Connector - (CHASSIS) 6 WAY TRANSPONDER-TIRE PRESSURE-RIGHT FRONT - (CHASSIS) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Description DESCRIPTION PREMIUM SYSTEM A transponder, also known as a trigger module, is located in three of the four wheel wells (behind the wheelhouse splash shields) of the vehicle to provide the WCM/SKREEM with the location of the tire pressure sensors on the vehicle. A fourth transponder is not necessary in the remaining wheel well due to the process-of-elimination theory. Once the system knows the location of the first three sensors it assumes the location of the fourth tire pressure sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Transponder - Description > Page 9966 Tire Pressure Monitor Receiver / Transponder: Description and Operation Tire Pressure Monitoring (TPM) Transponder - Operation OPERATION NUMBER: PREMIUM SYSTEM On vehicles equipped with the premium TPM system, the Wireless Control Module (WCM), commonly referred to as the Sentry Key Remote Entry Module (SKREEM), uses transponders (trigger modules) located in three of the four wheel wells on the vehicle to provide it with the location of the tire pressure sensors on the vehicle. Like the base system, the WCM receives RF signals from all four rotating wheel speed sensors. When the WCM needs to know which sensor is located at a particular location on the vehicle, it directs the transponder at that location to send out a low frequency signal to excite the nearby sensor. The WCM then receives that excited signal and knows where that sensor is located. This auto-locating process only happens in the first 10 minutes of any WCM cycle while traveling at speeds above 20 mph (32 km/h) (Each WCM cycle ends when the vehicle has been shut off for a time period of approximately 15 minutes or longer). Once the WCM has performed this to the three locations that have transponders (left front, right front, and left rear wheel wells), it uses the process-of-elimination theory to know that the fourth sensor ID signal is coming from the left rear tire sensor. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Removal Front FRONT TRANSPONDER 1. Raise and support the vehicle. 2. Remove the wheel well housing cover (2). 3. Remove the mounting nut (1) for the transponder (2). 4. Disconnect the electrical connector and remove the transponder (2) from the vehicle. Rear REAR TRANSPONDER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 9969 1. Raise and support the vehicle. 2. Remove the mounting nut (1) for the transponder (2). 3. Disconnect the electrical connector (3) and remove the transponder (2) from the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 9970 Tire Pressure Monitor Receiver / Transponder: Service and Repair Tire Pressure Monitoring (TPM) Transponder - Installation Front FRONT TRANSPONDER 1. Install the transponder (2) to the vehicle and reconnect the electrical connector. 2. Install the mounting nuts (1) for the transponder (2) Tighten to 3 Nm (25 in. lbs.). 3. Install the wheel well housing cover (2). 4. Lower the vehicle. Rear REAR TRANSPONDER Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Transponder - Removal > Page 9971 1. Install the transponder (2) to the vehicle and reconnect the electrical connector (3) and secure the harness to the stud (4). 2. Install the mounting nut (1) for the transponder (2). Tighten to 3 Nm (25 in. lbs.). 3. Lower the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service Precautions Tire Pressure Sensor: Service Precautions CAUTION CAUTION: The TPMS has been optimized for the original equipment tires and wheels. TPMS pressures have been established for the tire size equipped on your vehicle. Undesirable system operation or sensor damage may result when using replacement equipment that is not of the same size, type, and/or style. After-market wheels can cause sensor damage. Do not use aftermarket tire sealants or balance beads if your vehicle is equipped with a TPMS, as damage to the sensors may result. NOTE: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Tire pressure sensor valve stem caps and cores are specially designed for the sensors. Due to risk of corrosion, do not use a standard valve stem cap or core in a tire pressure sensor in place of the original equipment style sensor cap and core. CAUTION: After inspecting or adjusting the tire pressure always reinstall the valve stem cap. This will prevent moisture and dirt from entering the valve stem, which could damage the Tire Pressure Monitoring Sensor. CAUTION: Any time a sensor is to be reinstalled in a wheel, a new seal, cap and valve core must be installed on the stem to ensure air tight sealing. NOTE: TPM thresholds have been established for the original tire size equipped on the vehicle. Use original size tires only to maintain system accuracy. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Description DESCRIPTION NOTE: On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 or 433 MHz radio frequency. The 315 MHz sensors can be easily identified by a black sensor body, with (an oval insignia) (1). The 433 MHz sensors can be identified by a grey sensor body with an oval insignia. NOTE: If replacing the WCM, the spare tire must be dismounted from its wheel to access and note the spare tire pressure sensor ID. Then follow the programming steps outlined in the diagnostic scan tool for "Learn Spare Tire Sensor ID" under Miscellaneous Functions for the WCM wireless control module menu item as appropriate. In addition, the placard pressure thresholds must be updated in the new WCM. Go to "Update Pressure Thresholds" under Miscellaneous Functions for the WCM wireless control module and follow the procedure. On vehicles equipped with Tire Pressure Monitoring System, one tire pressure sensor (6) is mounted to each wheel in place of the traditional tire valve stem. Each sensor has an internal battery that lasts up to 10 years. The battery is not serviceable. At the time of battery failure, the sensor must be replaced. The TPM system operates on a 315 MHz radio frequency. The 315 MHz sensors can be easily identified by a black sensor body, with (an oval insignia) (1) and a grey valve cap (2). The Export TPM system operates on a 433 MHz radio frequency. The 433 MHz sensors can be easily identified by a gray sensor body (with an oval insignia) and a black valve cap (2). CAUTION: Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct sensor is being used. NOTE: Domestic vehicles, use the 315 MHz TPM sensors with the BLACK sensor body. For Export vehicles, use the 433 MHz TPM sensors with the GREY sensor body. Although 315 MHz and 433 MHz sensors are identical in size and shape, they are not interchangeable. Always make sure the correct color sensor is being used. A RKE-TPM Analyzer can be used to determine the sensor's frequency without having to dismount the tire. NOTE: If aftermarket wheels are installed and do not contain tire pressure sensors, the system will not function properly and the driver will be continuously notified of a system malfunction. The TPM sensors are designed for original style factory wheels. It is not recommended to install a tire pressure sensor in an aftermarket wheel. (This could cause sealing and system performance issues). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 9977 The serviceable components of the tire pressure sensor are: - Sensor-To-Wheel Seal (4) - Valve Stem Cap (2) - Valve Stem Core - Valve Stem Nut (3) The valve stem caps and cores used are specifically designed for the tire pressure monitoring sensors. Although similar to standard valve stem caps and cores, they are different. The valve stem cap has a special seal inside to keep moisture and corrosion out. The valve stem core has a special nickel coating to protect from corrosion. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Description and Operation > Tire Pressure Monitoring (TPM) Sensor - Description > Page 9978 Tire Pressure Sensor: Description and Operation Tire Pressure Monitoring (TPM) Sensor Operation OPERATION The battery operated tire pressure sensor is both a transmitter and a receiver. The TPM sensor can be forced to transmit if using a special tool such as a TPM-RKE Analyzer, or from a transponder. The TPM-RKE Analyzer has the ability to change the sensor's operating mode and to diagnose a faulty TPM sensor. Using a TPM-RKE Analyzer can take up to a minute to force a transmission from a sensor. The TPM sensor can be in one of the following modes: - Sleep Mode - A new TPM sensor will be in this mode. If placed on the vehicle as a road tire, the TPM sensor will transmit once every 20 seconds when the vehicle is driven at speeds over 15 mph (24 km/h). If the vehicle is not moving, the sensor will only transmit on a pressure change greater then 1 psi (6.9 kPA). Driving the vehicle continuously at speeds over 15 mph (24 km/h) for more then 4 minutes will change the sensor state into 30 BLOCK MODE. The TPM sensor will not return to SLEEP MODE. Now, if the vehicle has been stopped for 20 minutes, the TPM sensor state will change to PARK MODE. - Park Mode - This is the correct operating mode when the vehicle is not moving. The sensor will transmit once every 13 hours to update the WCM, or will transmit on a 1 PSI delta change. The sensors will internally take a measurement of the tire pressure every minute to determine a change in tire pressure 30 Block Mode - If the vehicle has been stopped for more then 20 minutes, or if the sensor's operating mode was forced to Park Mode using a TPM-RKE Analyzer, the sensor's operating mode will transition from Park Mode to 30 Block Mode once the vehicle is driven over 15mph. In this mode, the sensor will transmit once every 15 seconds when the vehicle is driven at speeds over 15 mph (24 km/h) for the first 30 transmissions. After about 8 minutes of continuous driving above 15 mph (24 km/h), the sensor's mode will change to Drive Mode - Drive Mode - In this mode, the sensor will transmit once every minute when the vehicle is driven at speeds over 15 mph (24 km/h). At any time that the vehicle speed drops below 15mph, the sensor will not transmit. The sensor mode will still be in drive mode when the sensor reaches speeds over 15 mph (24 km/h). If the vehicle has been stationary for more then 20 minutes, the TPM sensor will change to PARK MODE. Each sensor's (transmitter) broadcast is uniquely coded so that the wireless control module (WCM) can monitor the state of each of the sensors on the four rotating road wheels. The WCM can automatically learn and store the sensor's ID while driving "within 10 minutes continuously above 15 m.p.h. (24 Km/h)" after a sensor has been replaced, The vehicle must be stationary for more then 20 minutes in order to initiate the learning sequence. The sensor IDs can also be programmed using the TPM-RKE Analyzer Tool. Scan each TPM sensor at each road wheel, and store each Sensor ID in the correct location. (LEFT FRONT, LEFT REAR, RIGHT FRONT, and RIGHT REAR) Connect the TPM-RKE Analyzer Tool to the Scan Tool. Then follow the programming steps outlined in the diagnostic Scan Tool for "Program Tire Pressure Sensor ID w/ TPM Tool" under "MISC" for the "WCM/WIRELESS CONTROL MODULE". Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Removal REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly. CAUTION: The cap used on this valve stem contains an O-ring seal to prevent contamination and moisture from entering the valve stem. Do not substitute a regular valve stem cap in its place. CAUTION: The valve stem used on this vehicle is made of aluminum and the core is nickel plated brass. The original valve stem core must be reinstalled and not substituted with a valve stem core made of a different material. This is required to prevent corrosion in the valve stem caused by the different metals. 3. Dismount tire from wheel following tire changer manufacturers instructions while paying special attention to the following to avoid damaging the pressure sensor: a. When breaking the tire bead loose from the wheel rim, avoid using the Bead Breaker in the area of the sensor (1). That includes both outer and inner beads of the tire. b. When preparing to dismount the tire from the wheel, carefully insert the mounting/dismounting tool 280° from the valve stem ± 10°, then proceed to dismount the tire from the wheel. Use this process on both outer and inner tire beads. 4. Remove sensor nut (3) retaining sensor to wheel. While removing nut, hold pressure against rear of metal valve stem to keep valve stem from pushing rearward, damaging antenna strap. 5. Remove sensor (1) from wheel (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 9981 Tire Pressure Sensor: Service and Repair Tire Pressure Monitoring (TPM) Sensor - Installation INSTALLATION NOTE: Before reinstalling an existing tire pressure sensor, replace seal (2) and metal washer (1) at base of sensor valve stem (6) to ensure proper sealing. 1. Wipe area clean around sensor/valve stem mounting hole in wheel (5). Make sure surface of wheel is not damaged. CAUTION: To avoid damaging sensor antenna strap (1), if equipped, hold pressure against rear of metal valve stem (2) while sensor is inserted through wheel mounting hole and nut is installed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 9982 2. Insert sensor (1) through wheel (2) as shown keeping pressure against rear of metal valve stem (See Arrow). Potted side of sensor is to be positioned toward wheel. Do not attempt to mount sensor otherwise, damage may occur. 3. Install sensor nut (with pressed-in washer) (3) by hand. NOTE: Before tightening sensor nut, push downward on sensor housing (2) in an attempt to make it flush with interior contour of wheel (1). 4. While holding sensor in position, tighten sensor nut to 6 Nm (53 in. lbs.). CAUTION: Over-torquing the sensor nut by as little as 12 Nm (106 in. lbs.) may result in sensor separation from the valve stem. Under this condition, the sensor may still function. However, the condition should be corrected immediately. 5. Mount tire on wheel following tire changer manufacturers instructions, paying special attention to the following to avoid damaging tire pressure sensor: a. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 9983 Rotating Wheel Tire Changers - Once the wheel is mounted to the changer, position the sensor valve stem (2) approximately 280° from the head of the changer (located at 1) in a clockwise direction before rotating the wheel (also in a clockwise direction) to mount the tire. Use this procedure on both the outer and inner tire beads. b. Rotating Tool Tire Changers - Position the wheel on the changer so that the sensor valve stem (1) is located approximately 210° clockwise from the installation end of the mounting/dismounting tool (2) once the tool is mounted for tire installation. Make sure the sensor is clear of the lower bead breaker area (3) to avoid damaging the sensor when the breaker rises. Rotate the tool (2) in a counterclockwise direction to mount the tire. Use this procedure on both the outer and inner tire beads. 6. Adjust air pressure to that listed on Tire Inflation Pressure Label (Placard) provided with vehicle (usually applied to driver's side B-pillar). Make sure original style valve stem cap is securely installed to keep moisture out of sensor. 7. Install tire and wheel assembly on vehicle. 8. Remove the support and lower the vehicle. 9. Perform one of the following to make the system learn the new sensor ID. a. Use the TPM-RKE Analyzer, 9936, with the Scan Tool to program the WCM/SKREEM with the tire pressure sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Service and Repair > Tire Pressure Monitoring (TPM) Sensor - Removal > Page 9984 b. Once the vehicle has remained stationary for more than 20 minutes, drive vehicle for a minimum of 10 minutes while maintaining a continuous speed above 15 mph (24 km/h). During this time, the system will learn the new sensor ID. This is part of the TPM Diagnostic Verification Test. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Verification Tests/Tire Pressure Monitor (TPM) Verification Test NOTE: If a sensor cannot be trained, refer to appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Description and Operation > ESP With BAS Indicator - Description Traction Control Indicator Lamp: Description and Operation ESP With BAS Indicator - Description DESCRIPTION An Electronic Stability Program/Brake Assist System (ESP/BAS) indicator is standard equipment on all instrument clusters. This indicator is located in the center of the speedometer, in the area below and to the left of the speedometer needle hub. The ESP/BAS indicator consists of a stencil-like cutout of the text ESP BAS in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The ESP/BAS indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Description and Operation > ESP With BAS Indicator - Description > Page 9989 Traction Control Indicator Lamp: Description and Operation ESP With BAS Indicator - Operation OPERATION The ESP/BAS indicator gives an indication to the vehicle operator when a problem has been detected in the Electronic Stability Program (ESP)/Brake Assist System (BAS). This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) and the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The ESP/BAS indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the LED is always off when the ignition switch is in any position except ON or START. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster will turn on the ESP/BAS indicator for the following reasons: - Bulb Test - Each time the ignition switch turns to the on position the ESP/BAS indicator illuminates for about four seconds as a bulb test. - ESP/BAS Indicator Lamp-On Message - Each time the cluster receives an electronic ESP/BAS indicator lamp-on message from the CAB or the FCM, the ESP/BAS indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB or FCM, or until the ignition switch is turned to the off position, whichever occurs first. self Test - Each time the cluster is put through the self test, the ESP/BAS indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CAB and FCM continually monitor the ESP/BAS system circuits and sensors to decide whether the system is in good operating condition and the proper outputs to the components of the system. The CAB or FCM then sends the proper lamp-ON or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). Use a diagnostic scan tool for proper diagnosis of the ESP/BAS system, the CAB, the FCM, the CCN, the CAN data bus or the electronic communication related to ESP/BAS indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Description and Operation > ESP With BAS Indicator - Description > Page 9990 Traction Control Indicator Lamp: Description and Operation Traction Control Indicator - Description DESCRIPTION An Electronic Stability Program/Brake Assist System (ESP/BAS)/Traction Control System (TCS) traction control indicator is standard equipment on all instrument clusters. This indicator is located in the center of the speedometer, in the area above and to the right of the speedometer needle hub. The traction control indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Stability - Anti-Spin in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. An amber Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in amber through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The traction control indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp > Component Information > Description and Operation > ESP With BAS Indicator - Description > Page 9991 Traction Control Indicator Lamp: Description and Operation Traction Control Indicator - Operation OPERATION The traction control indicator gives an indication to the vehicle operator when the Electronic Stability Program (ESP)/Brake Assist System (BAS)/Traction Control System (TCS) has been activated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Controller Antilock Brake (CAB) over the Controller Area Network (CAN) data bus. The traction control indicator is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator is always off when the ignition switch is in any position except ON or START. The indicator only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the traction control indicator for the following reasons: - Bulb Test - Each time the ignition switch is turned to the ON position the traction control indicator is illuminated for about four seconds as a bulb test. The entire bulb test is a function of the CAB. - Traction Control Indicator Lamp-On Message - Each time the cluster receives an electronic traction control indicator lamp-on message from the CAB indicating that the ESP/BAS/TCS has been activated, the traction control indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-off message from the CAB, or until the ignition switch is turned to the OFF position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the traction control indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The CAB continually monitors the status of the inputs to the ESP/BAS/TCS systems to determine the proper outputs to the components of the Antilock Brake System (ABS). The CAB then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the traction control indicator or the instrument cluster circuitry that controls the indicator, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the ESP/BAS/TCS, the CAB, the CCN, the CAN data bus or the electronic communication related to traction control indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Description and Operation > Transmission Range Indicator - Description Transmission Shift Position Indicator Lamp: Description and Operation Transmission Range Indicator - Description DESCRIPTION An electronic automatic transmission gear selector indicator is standard factory-installed equipment on this vehicle. The gear selector indicator information is displayed in an electronic, blue-green Vacuum-Fluorescent Display (VFD) unit. This VFD unit is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located below the tachometer in the lower right area of the cluster overlay. The dark lens over the VFD prevents the indicator from being clearly visible when it is not illuminated. The gear selector indicator displays the following characters from left to right: P, R, N, D, 2, and 1. Each character appears in a blue-green color and at the same lighting level as the odometer information. Respectively, these characters represent the PARK, REVERSE, NEUTRAL, DRIVE, second gear, and first gear positions of the transmission gear selector lever on the steering column. The indicator also illuminates a rectangular box around the character that represents the currently selected lever position. During daylight hours (exterior lamps are OFF) the gear selector indicator is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the indicator lighting level is adjusted with the other cluster general illumination lamps using the panel lamps dimmer thumbwheel on the headlamp switch. However, a PARADE mode position of the panel lamps dimmer thumbwheel allows the indicator to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The gear selector indicator is serviced as a unit with the VFD unit in the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Description and Operation > Transmission Range Indicator - Description > Page 9996 Transmission Shift Position Indicator Lamp: Description and Operation Transmission Range Indicator - Operation OPERATION The electronic gear selector indicator gives an indication to the vehicle operator of the transmission gear that has been selected with the automatic transmission gear selector lever. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received from the Powertrain Control Module (PCM) over the Controller Area Network (CAN) data bus. The gear selector indicator information is displayed by the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit soldered onto the instrument cluster electronic circuit board, and the VFD will not display the gear selector indicator information after the ignition switch turns to the off position. Each time the cluster is disconnected from battery current for more than about five minutes, it must configure itself for the automatic transmission type that is in the vehicle once it is reconnected to battery current. The instrument cluster circuitry operates the gear selector indicator to provide the following features: - Selected Gear Message - Each time the cluster receives an electronic selected gear message from the PCM, a box illuminates around the appropriate character in the gear selector indicator. The box remains illuminated until the cluster receives a different selected gear message, or until the ignition switch turns to the off position, whichever occurs first. - Communication Error - If the cluster fails to receive a selected gear message from the PCM within three seconds, the instrument cluster circuitry displays all gear selector positions boxed (selected) until a valid selected gear message is received or until the ignition switch turns to the off position, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the odometer/trip odometer VFD displays all of its characters at once, then step through each character segment individually during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The PCM continually monitors a hardwired multiplex input from the Transmission Range Sensor (TRS), then sends the proper message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the gear selector indicator or the instrument cluster circuitry that controls this function, See: Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the TRS, the PCM, the CCN, the CAN data bus or the electronic communication related to gear selector indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Description and Operation Backup Lamp Switch: Description and Operation DESCRIPTION Vehicles with an electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The TRS is described in further detail elsewhere in this service information. Refer to the service and diagnostic information for the automatic transmission type installed in the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Locations > Page 10006 Brake Lamp Relay: Diagrams Connector (IN PDC) RELAY-STOP LAMP ACTIVATION (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Description and Operation > Stop Lamp Inhibit Relay - Description Brake Lamp Relay: Description and Operation Stop Lamp Inhibit Relay - Description DESCRIPTION Vehicles equipped with an optional Electronic Stability Program (ESP)/Traction Control System (TCS) package have a stop lamp inhibit relay. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through four integral male spade-type terminals that extend from the relay base plate. The stop lamp inhibit relay is located in the Junction Block (JB) in the passenger compartment on the driver side cowl side inner panel below the end of the instrument panel. The stop lamp inhibit relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Lamp Relay > Component Information > Description and Operation > Stop Lamp Inhibit Relay - Description > Page 10009 Brake Lamp Relay: Description and Operation Stop Lamp Inhibit Relay - Operation OPERATION The stop lamp inhibit relay is an electromechanical switch that uses a low current input from the Controller Antilock Brake (CAB) to interrupt a high current output from the brake lamp switch to the brake lamps. Within the relay is an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the stop lamp inhibit relay include: - Common Supply Terminal (30) - The common feed terminal is connected to the output of the brake lamp switch at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a control output of the CAB through a stop lamp inhibit relay control circuit. The CAB controls brake lamp operation by controlling a ground path through this circuit. - Coil Battery Terminal (86) - The coil battery terminal is connected to a fused ignition switch output (run-start) circuit at all times. - Normally Closed Terminal (87A) - The normally closed terminal is connected to the brake lamps through a brake lamp switch output circuit and provides battery voltage to the brake lamps whenever the relay is de-energized. The stop lamp inhibit relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal Brake Light Bulb: Service and Repair Tail Stop Turn Lamp Bulb - Removal BULB - DODGE NOTE: The rear lamp unit contains four bulbs: side marker, tail/brake, tail/turn, and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the rear lamp unit (1) from the end of the quarter panel. See: Service and Repair/Tail Stop Turn Lamp - Removal. 3. Remove the three screws (3) that secure the socket plate (2) to the back of the rear lamp unit housing. 4. Remove the socket plate from the rear lamp. 5. Pull the base of the backup (1), tail/turn (2), tail/brake (3), or side marker (4) lamp bulb straight out of the appropriate socket in the socket plate (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal > Page 10014 Brake Light Bulb: Service and Repair Tail Stop Turn Lamp Bulb - Installation BULB - DODGE CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The rear lamp unit contains four bulbs: side marker, tail/brake, tail/turn, and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the backup (1), tail/turn (2), tail/brake (3), or side marker (4) lamp bulb with the appropriate socket in the socket plate (5). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket plate (2) and bulbs with the openings on the back of the rear lamp unit housing (1). 4. Insert the socket plate and bulbs straight into the housing until the plate is firmly seated. 5. Install and tighten the three screws (3) that secure the socket plate to the housing. Tighten the screws to 1 Nm (12 in. lbs.). 6. Reinstall the rear lamp unit onto the end of the quarter panel. See: Service and Repair/Tail Stop Turn Lamp - Installation. 7. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10018 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10019 Brake Light Switch: Diagrams Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-STOP LAMP - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description Brake Light Switch: Description and Operation Stop Lamp Switch - Description DESCRIPTION The brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured to the steering column support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the instrument panel wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. An installed brake lamp switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or removed from its mounting position for any reason, it must be replaced with a new unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description > Page 10022 Brake Light Switch: Description and Operation Stop Lamp Switch - Operation OPERATION The brake lamp switch controls three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the brake lamps and the Controller Antilock Brake (CAB) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a brake lamp switch sense circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Powertrain Control Module on a speed control supply circuit, and supplies this battery voltage to the speed control servo solenoids (dump, vacuum, and vent) on a speed control brake switch output circuit only when the speed control system is turned ON and the brake pedal is released (brake lamp switch plunger is depressed). The components of the self-adjusting brake switch plunger consist of a two-piece telescoping plunger, a split plunger locking collar, and a release wedge. The release lever has a shaft with a wedge that spreads the plunger locking collar to an open or released position. After the switch is installed and the brake pedal is released, the plunger telescopes to the correct adjustment position. When the release lever is moved to the release position, the wedge is disengaged from the locking collar causing the collar to apply a clamping pressure to the two plunger halves, fixing the plunger length. The brake lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 10023 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. CAUTION: Do not remove the brake lamp switch from the mounting bracket. The self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the ineffective brake lamp switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal Brake Light Switch: Service and Repair Stop Lamp Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Locate the brake lamp switch (1) near the support bracket on the lower steering column (3). 3. Disconnect the wire harness connector (5) from the brake lamp switch. 4. Rotate the brake lamp switch housing clockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the switch mounting bracket (4). 5. Pull the switch straight back from the keyed hole to remove it from the bracket. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 6. Discard the removed brake lamp switch . Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal > Page 10026 Brake Light Switch: Service and Repair Stop Lamp Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. CAUTION: The brake lamp switch plunger MUST be in the fully extended position prior to releasing the brake pedal or setting the plunger length to ensure proper switch adjustment and operation. Do not manually press the plunger into the switch body prior to or during switch installation, and do not pull the brake pedal upward prior to setting the plunger length using the plunger adjustment release lever as described in the following procedure. 1. Depress and hold the brake pedal in the depressed position. 2. Align the tabs on the brake lamp switch locking collar with the keyed hole in the switch mounting bracket (4) on the lower steering column (3). 3. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the switch mounting bracket until the switch housing (1) is firmly seated against the bracket. 4. Rotate the switch housing counterclockwise about 30 degrees to engage the tabs on the locking collar with the switch mounting bracket. CAUTION: Release, but do not pull up on the brake pedal before the switch plunger adjustment has been completed. 5. Release the brake pedal, but do not pull it upward. CAUTION: Be certain that the brake lamp switch plunger is in contact with the flag bracket on the brake pedal arm prior to rotating the plunger adjustment release lever. If the plunger is not contacting the flag bracket, depress and hold the brake pedal while manually pulling the plunger out from the switch body to the fully extended position. Then release the brake pedal, but do not pull it upward. 6. Rotate the plunger adjustment release lever (2) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch must be installed. 7. Reconnect the wire harness connector (5) to the brake lamp switch. 8. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair > Center Mounted Brake Lamp Bulb - Removal Center Mounted Brake Lamp Bulb: Service and Repair Center Mounted Brake Lamp Bulb Removal BULB 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the Center High Mounted Stop Lamp (CHMSL) (1) from the liftgate header panel. See: Service and Repair/Center Mounted Brake Lamp - Removal. 3. Disconnect the wire harness connector (2) from the socket (3) on the back of the CHMSL housing. 4. Firmly grasp the socket on the back of the housing and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb straight out of the socket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb > Component Information > Service and Repair > Center Mounted Brake Lamp Bulb - Removal > Page 10032 Center Mounted Brake Lamp Bulb: Service and Repair Center Mounted Brake Lamp Bulb Installation BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the base of the bulb with the CHMSL socket (3). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of CHMSL housing (1). 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reconnect the wire harness connector (2) to the socket. 7. Reinstall the CHMSL onto the liftgate header panel. See: Service and Repair/Center Mounted Brake Lamp - Installation. 8. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Liftgate Lamp Bulb - Removal Courtesy Lamp Bulb: Service and Repair Liftgate Lamp Bulb - Removal BULB NOTE: Two versions of the liftgate lamp are available: one using an incandescent bulb for illumination, and one using a Light Emitting Diode (LED) unit for illumination. The external appearance of the two lamp units is the same as are the service procedures for removing and installing the lamp or the lamp lens. Only the light source is different. The incandescent bulb is serviceable using the following procedure; however, if an LED unit or the printed circuit board to which the LED is soldered is damaged or ineffective, the entire lamp unit must be replaced. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Using a small thin-bladed screwdriver, gently pry between the lamp lens (2) and the lamp housing (1) at the two upper or lower snap features to remove the lens from the housing. 3. Disengage the ends of the bulb (3) from the two bulb holders within the lamp housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Liftgate Lamp Bulb - Removal > Page 10038 Courtesy Lamp Bulb: Service and Repair Liftgate Lamp Bulb - Installation BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: Two versions of the liftgate lamp are available: one using an incandescent bulb for illumination, and one using a Light Emitting Diode (LED) unit for illumination. The external appearance of the two lamp units is the same as are the service procedures for removing and installing the lamp or the lamp lens. Only the light source is different. The incandescent bulb is serviceable using the following procedure; however, if an LED unit or the printed circuit board to which the LED is soldered is damaged or ineffective, the entire lamp unit must be replaced. 1. Install the ends of the bulb (3) onto the two bulb holders within the liftgate lamp housing (1). 2. Align the lamp lens (2) with the lamp housing, then use firm and even hand pressure to snap the lens onto the housing. 3. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Dome Lamp - Removal Dome Lamp Bulb: Service and Repair Dome Lamp - Removal Front BULB - FRONT 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the front dome lamp unit (2) from the headliner. See: Service and Repair/Dome Lamp Removal. 3. With the lamp lens (1) in the open position, carefully unsnap the bulb (3) from the two bulb holders within the front dome lamp housing. Rear BULB - REAR 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Insert the tip of a small flat-bladed screwdriver into the notch on one side of the rear dome lamp between the lens (4) and the lamp housing (1). 3. Gently pry the notched edge of the lens downward until it unsnaps from the housing. 4. Swing the notched end of the lens downward far enough to access the bulb (3). 5. Carefully unsnap the bulb from the two bulb holders within the rear dome lamp housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and Repair > Dome Lamp - Removal > Page 10044 Dome Lamp Bulb: Service and Repair Dome Lamp - Installation Front BULB - FRONT CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. With the dome lamp lens (1) in the open position, align the ends of the bulb (3) with the two bulb holders within the front dome lamp housing (2). 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Reinstall the lamp into the headliner. See: Service and Repair/Dome Lamp - Installation. 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Rear BULB - REAR CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the ends of the bulb (3) with the two bulb holders within the rear dome lamp housing (1). 2. Carefully press the bulb firmly and evenly into the bulb holders until it snaps into place. 3. Swing the notched end of the lens (4) up into position against the housing, then press upward on the lens firmly and evenly until it snaps into the housing. 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Description and Operation > Door Ajar Switch - Description Door Switch: Description and Operation Door Ajar Switch - Description DOOR This vehicle has four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Latch/Service and Repair/Front Door Latch - Removal or See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Rear Door Latch - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Description and Operation > Door Ajar Switch - Description > Page 10049 Door Switch: Description and Operation Door Ajar Switch - Operation DOOR The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The rear door ajar switches are hard wired in series between a body ground and the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). On vehicles not equipped with the optional memory system, the front door ajar switches are also hard wired in series between ground and the EMIC. On vehicles equipped with the optional memory system each front door ajar switch is hard wired in series between ground and its respective driver or passenger Memory Mirror Module (MMM) located in the front door. The MMM then sends electronic door ajar switch status messages to the EMIC over the Controller Area Network (CAN) data bus. Both the EMIC and the MMM read the hard wired door ajar switch inputs through internal pull-ups, then use these inputs to control many electronic functions and features of the vehicle. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Fog Lamp Bulb - Removal Fog/Driving Lamp Bulb: Service and Repair Fog Lamp Bulb - Removal BULB CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the fasteners that secure the front of the front fender wheel house liner to the bottom of the front fascia. See: Body and Frame/Fender/Front Fender/Service and Repair/Front Fender - Removal. 3. Pull the front of the front fender liner rearward far enough to access the back of the front fascia. 4. Reach under and behind the front fascia to access the front fog lamp housing on the back of the front fascia. 5. Disconnect the wire harness connector (1) from the fog lamp bulb connector receptacle. 6. Firmly grasp the bulb on the back of the housing and rotate it counterclockwise (2) about 30 degrees to unlock it. 7. Pull the bulb straight out from the keyed opening in the housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service and Repair > Fog Lamp Bulb - Removal > Page 10055 Fog/Driving Lamp Bulb: Service and Repair Fog Lamp Bulb - Installation BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Align the base of the fog lamp bulb with the keyed opening on the back of the front fog lamp housing. 2. Insert the bulb into the housing until the base is firmly seated. 3. Rotate the bulb clockwise (2) about 30 degrees to lock it into place. The bulb connector receptacle should be oriented in a horizontal position. 4. Position the front of the front fender wheel house liner to the bottom of the front fascia. 5. Reinstall the fasteners that secure the front of the wheel house liner to the bottom of the front fascia. See: Body and Frame/Fender/Front Fender/Service and Repair/Front Fender - Installation. 6. Reconnect the wire harness connector (1) to the bulb. 7. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Indicator > Component Information > Description and Operation > Fog Lamp Indicator - Description Fog/Driving Lamp Indicator: Description and Operation Fog Lamp Indicator - Description DESCRIPTION A fog lamp indicator is standard equipment on all instrument clusters. However, on vehicles not equipped with optional fog lamps, this indicator is electronically disabled. This indicator is located within the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. The fog lamp indicator consists of the International Control and Display Symbol icon for Front Fog Light in the lower left corner of the VFD unit. The VFD unit is soldered onto the instrument cluster electronic circuit board, and is visible through a window with a smoked clear lens located on the lower edge of the speedometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents the icon from being clearly visible when it is not illuminated. The fog lamp indicator icon appears in a blue-green color and at the same lighting level as the odometer information when it is illuminated by the instrument cluster electronic circuit board. During daylight hours (exterior lamps are OFF) the VFD unit is illuminated at full brightness for clear visibility. At night (exterior lamps are ON), the VFD unit lighting level is adjusted with the other cluster illumination lamps using the panel lamps dimmer function of the interior lighting thumbwheel on the headlamp switch. However, a PARADE mode position of the thumbwheel allows the VFD unit to be illuminated at full brightness if the exterior lamps are turned ON during daylight hours. The fog lamp indicator is serviced as a unit with the VFD unit in the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Indicator > Component Information > Description and Operation > Fog Lamp Indicator - Description > Page 10060 Fog/Driving Lamp Indicator: Description and Operation Fog Lamp Indicator - Operation OPERATION The fog lamp indicator gives an indication to the vehicle operator whenever the optional fog lamps are illuminated. This indicator is controlled by the instrument cluster circuit board based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The fog lamp indicator is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate whenever the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the indicator is always off when the ignition switch is in any position except ON or START. The indicator only illuminates when it is energized by the instrument cluster logic circuit. The instrument cluster turns on the fog lamp indicator for the following reasons: - Fog Indicator Lamp-On Message - Each time the cluster receives an electronic fog indicator lamp-on message from the FCM indicating the fog lamp relay is energized, the fog lamp indicator illuminates. The indicator remains illuminated until the cluster receives a lamp-OFF message from the FCM, until the ignition switch is turned to the OFF position or until the exterior lamp load shedding (battery saver) timed interval expires, whichever occurs first. - Actuator Test - Each time the cluster is put through the actuator test, the fog lamp indicator turns on, then off again during the VFD portion of the test to confirm the functionality of the VFD and the cluster control circuitry. The FCM continually monitors electronic exterior lighting switch status messages from the instrument cluster, also known as the Cab Compartment Node (CCN) to determine the appropriate outputs to the fog lamp relay. The FCM activates or deactivates the fog lamp relay then sends the proper lamp-on or lamp-off message back to the CCN. For further diagnosis of the fog lamp indicator or the instrument cluster circuitry that controls the indicator, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the fog lamp system, the FCM, the CCN, the CAN data bus or the electronic communication related to fog lamp indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Fog Lamp Relay is located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 10064 Fog/Driving Lamp Relay: Diagrams Connector (IN IPM) RELAY-FOG LAMP (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Description and Operation > Front Fog Lamp Relay - Description Fog/Driving Lamp Relay: Description and Operation Front Fog Lamp Relay - Description DESCRIPTION The front fog lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The front fog lamp relay is located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The front fog lamp relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Description and Operation > Front Fog Lamp Relay - Description > Page 10067 Fog/Driving Lamp Relay: Description and Operation Front Fog Lamp Relay - Operation OPERATION The front fog lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to the front fog lamps. Within the relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the front fog lamp relay include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a fog lamp relay control circuit. The FCM controls front fog lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the front fog lamps through a fog lamp relay output circuit and provides battery voltage to the front fog lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The front fog lamp relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 10072 Hazard Warning Switch: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Front Lamp Unit Bulb - Removal Headlamp Bulb: Service and Repair Front Lamp Unit Bulb - Removal BULB - HEADLAMP CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the front lamp unit (1) from the front fender, but do not disconnect the headlamp and dash wiring from the back of the lamp housing. See: Service and Repair/Front Lamp Unit - Removal. 3. Disconnect the headlamp and dash wire harness connector from the headlamp bulb (3) on the back of the front lamp unit housing. 4. Firmly grasp the headlamp bulb and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the bulb straight out from the keyed opening in the housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Front Lamp Unit Bulb - Removal > Page 10078 Headlamp Bulb: Service and Repair Front Lamp Unit Bulb - Installation BULB - HEADLAMP CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. CAUTION: Do not contaminate the bulb glass by touching it with your fingers or by allowing it to contact other oily surfaces. Shortened bulb life will result. 1. Align the headlamp bulb (3) with the keyed opening on the back of the front lamp unit (1) housing. 2. Insert the bulb into the housing until it is firmly seated. 3. Rotate the bulb clockwise about 30 degrees to lock it into place. 4. Reconnect the headlamp and dash wire harness connector to the headlamp bulb. 5. Reinstall the front lamp unit into the front fender. See: Service and Repair/Front Lamp Unit - Installation. 6. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 10082 Headlamp Dimmer Switch: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Description and Operation > Multifunction Switch - Description Headlamp Dimmer Switch: Description and Operation Multifunction Switch - Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Front Washer Control - The multi-function switch control knob provides a momentary front WASH position for front washer system operation. - Front Wiper Control - The multi-function switch control knob provides two continuous front wipe switch positions, LOW speed or HIGH speed; and an intermittent front wipe mode with five delay interval positions. Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Description and Operation > Multifunction Switch - Description > Page 10085 Headlamp Dimmer Switch: Description and Operation Multifunction Switch - Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control front washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control front wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Front Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the front WASH mode. The washer pump will continue to operate in the front washer mode until the control knob is released or for 10 continuous seconds, whichever occurs first. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front washer switch status messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The FCM responds by energizing or de-energizing the washer pump in the front washer mode. - Front Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous front wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front wiper switch status messages to the FCM over the CAN data bus. The FCM responds by energizing or de-energizing the wiper on/off and high/low relays in the Power Distribution Center (PDC) for front wiper system control. - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the FCM over the CAN data bus. The FCM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the FCM over the CAN data bus. The FCM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the FCM over the CAN data bus. The FCM energizes and flashes or de-energizes the selected left or right turn signal circuits. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Description and Operation > Page 10086 Headlamp Dimmer Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the multi-function switch from the switch mounting housing on the steering column. See: Sensors and Switches - Lighting and Horns/Combination Switch/Service and Repair/Multifunction Switch - Removal. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Service and Repair > Multifunction Switch - Removal Headlamp Dimmer Switch: Service and Repair Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10089 8. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 9. Rotate the steering wheel far enough to access and remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 10. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10090 Headlamp Dimmer Switch: Service and Repair Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Rotate the steering wheel far enough to install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. Be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10091 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations > Page 10095 Headlamp Switch: Diagrams Connector - (INSTRUMENT PANEL) 10 WAY SWITCH-HEADLAMP - (INSTRUMENT PANEL) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch - Description Headlamp Switch: Description and Operation Headlamp Switch - Description DESCRIPTION The headlamp switch (1) is located on the instrument panel, to the left of the steering column. Three different switches are used. The standard switch features a three-position rotary knob (4) for exterior lighting control and a thumbwheel (2) for panel lamps dimming and interior lighting control. An optional switch has a momentary push button (3) added for front fog lamp control. A second optional switch has the same thumbwheel and momentary push button, but has a fourth position added to the rotary knob for selecting the optional automatic headlamps feature. Each of these switches is constructed of molded plastic. The rotary knob is molded plastic and knurled around its circumference to ease operator control. The thumbwheel is also plastic and knurled. The optional front fog lamp push button is plastic with a smooth finish and an International Control and Display Symbol icon for Front Fog Light applied to it. The switch face plate is also labeled with graphics and icons to clearly identify the many functions of the rotary knob and thumbwheel. Three screws secure the switch to the back of the cluster bezel through integral mounting flanges that are molded to each side of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A panel dimmer controlled incandescent bulb soldered to the circuit board within the switch provides back lighting for visibility at night, but is not serviceable. The headlamp switch cannot be repaired and, if ineffective or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch - Description > Page 10098 Headlamp Switch: Description and Operation Headlamp Switch - Operation OPERATION The headlamp switch uses two resistor multiplexed outputs to control the many functions and features it provides. The switch receives a clean ground from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a headlamp switch return circuit. It then provides outputs to the EMIC on a headlamp switch signal circuit to control exterior lighting functions, and on a panel lamps dimmer signal circuit to control panel dimmer and interior lighting functions. The switch illumination circuit receives a path to ground at all times through the left instrument panel ground circuit. The illumination level is controlled by a Pulse-Width Modulated (PWM) output received from the EMIC on a headlamp switch illumination control circuit. The EMIC controls this output based upon the dimmer signal select mux input from the headlamp switch. The headlamp switch operates as follows: - Front Fog Lamps Control - For vehicles so equipped, the fog lamp push button on the headlamp switch is depressed to activate or deactivate the optional front fog lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic fog lamp switch status messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The FCM responds by energizing or de-energizing the front fog lamp relay in the Power Distribution Center (PDC) and by sending an electronic message back to the EMIC to control the front fog lamp indicator. - Exterior Lighting Control - The rotary knob on the headlamp switch is rotated to a detent position to activate or deactivate the exterior lighting. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic exterior lighting switch status messages to the FCM over the CAN data bus. The FCM responds by energizing or de-energizing the park lamp relay in the PDC and the high or low beam headlamp circuits, and by sending an electronic message back to the EMIC to control the high beam indicator. The FCM also remembers which headlamp beams were last selected using the multi-function switch, and energizes those beams by default the next time the headlamps are turned ON. If the vehicle is equipped with optional automatic headlamps and the A (Automatic) position is selected, the EMIC also monitors an input from a sun load sensor on the instrument panel and, based upon the monitored ambient light levels, responds by automatically sending appropriate messages to the FCM to turn the exterior lighting ON or OFF while the ignition switch is in the ON position. - Interior Lighting Control - The thumbwheel on the headlamp switch is rotated to the dome DEFEAT, dome ON, PARADE mode, or one of the six panel dimmer detent positions to control the interior courtesy/dome and panel lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate interior lighting control outputs through its internal courtesy lamp driver circuits, electronic dimming level messages to other modules over the CAN data bus, and the proper PWM outputs to control dimming levels through several panel dimmer illumination control driver circuits. The headlamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Description and Operation > Page 10099 Headlamp Switch: Testing and Inspection HEADLAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the cluster bezel and the headlamp switch from the instrument panel as a unit. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Cluster Bezel - Removal. 2. Disconnect the wire harness connector from the back of the headlamp switch. 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective headlamp switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch - Removal Headlamp Switch: Service and Repair Headlamp Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the cluster bezel (1) from the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Cluster Bezel - Removal. 3. Disconnect the wire harness connector from the back of the headlamp switch (2). 4. Place the cluster bezel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the bezel from cosmetic damage. 5. Remove the three screws (3) that secure the headlamp switch to the back of the cluster bezel. 6. Remove the headlamp switch from the cluster bezel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch - Removal > Page 10102 Headlamp Switch: Service and Repair Headlamp Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the headlamp switch (2) to the back of the cluster bezel (1). 2. Install and tighten the three screws (3) that secure the headlamp switch to the cluster bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Position the cluster bezel close enough to the instrument panel to reconnect the wire harness connector to the back of the headlamp switch. 4. Reinstall the cluster bezel onto the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Cluster Bezel - Installation. 5. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation > High Beam Indicator Lamp - Description Hi-Beam Indicator Lamp: Description and Operation High Beam Indicator Lamp - Description DESCRIPTION A high beam indicator is standard equipment on all instrument clusters. This indicator is located near the upper edge of the instrument cluster, between the minor gauge set and the speedometer. The high beam indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for High Beam in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents the indicator from being clearly visible when it is not illuminated. A blue Light Emitting Diode (LED) behind the cutout in the opaque layer of the overlay causes the indicator to appear in blue through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The high beam indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Hi-Beam Indicator Lamp > Component Information > Description and Operation > High Beam Indicator Lamp - Description > Page 10107 Hi-Beam Indicator Lamp: Description and Operation High Beam Indicator Lamp - Operation OPERATION The high beam indicator gives an indication to the vehicle operator whenever the headlamp high beams are illuminated. This indicator is controlled by a transistor on the instrument cluster circuit board based upon cluster programming and a hardwired multiplex input received by the cluster from the headlamp beam select switch circuitry of the multifunction switch on the washer/beam select switch mux circuit. The high beam indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, the LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the high beam indicator for the following reasons: - High Beam Headlamps-On Input - Each time the cluster detects a high beam headlamps-on input from the headlamp beam select switch circuitry of the multifunction switch on the washer/beam select switch mux circuit, the headlamp high beams and the high beam indicator illuminates. The indicator remains illuminated until the cluster receives a high beam headlamps-on input from the multifunction switch, or until the exterior lamp load shedding (battery saver) timed interval expires, whichever occurs first. - Self Test - Each time the cluster is put through the self test, the high beam indicator turns on, then off again during the bulb check portion of the test to confirm the functionality of the LED and the cluster control circuitry. The instrument cluster, also known as the Cab Compartment Node (CCN) continually monitors the headlamp switch and the multifunction switch to determine the proper headlamp low beam and high beam control. The CCN then sends the proper electronic low beam, high beam lamp-on and lamp-off messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus and controls the high beam indicator operation accordingly. For further diagnosis of the high beam indicator or the instrument cluster circuitry that controls the indicator, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use conventional diagnostic tools and procedures for the hardwired headlamp switch and multifunction switch inputs and circuits related to high beam indicator operation. Refer to the appropriate wiring information. Use a diagnostic scan tool for proper diagnosis of the FCM, the CCN, the CAN data bus or the electronic communication related to high beam indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Horn Relay is located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 10112 Horn Relay: Diagrams Connector (IN IPM) RELAY-HORN (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 10116 Horn Switch: Diagrams Connector - (STEERING WHEEL) 2 WAY SWITCH-HORN - (STEERING WHEEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Locations > Page 10117 Horn Switch: Testing and Inspection HORN SWITCH The most reliable, efficient and accurate means to diagnose the horn system requires the use of a scan tool and the proper diagnostic procedure information. For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair > License Plate Lamp Bulb - Removal License Plate Bulb: Service and Repair License Plate Lamp Bulb - Removal BULB 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the license plate lamp (3) from the mounting hole in the underside of the exterior liftgate handle (2). See: Service and Repair/License Plate Lamp - Removal. 3. Pull the base of the bulb straight out of the socket (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information > Service and Repair > License Plate Lamp Bulb - Removal > Page 10123 License Plate Bulb: Service and Repair License Plate Lamp Bulb - Installation BULB CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. 1. Align the base of the bulb with the license plate lamp socket (1). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Reinstall the lamp (3) into the mounting hole on the underside of the exterior liftgate handle (2). See: Service and Repair/License Plate Lamp Installation. 4. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Left Front Side Marker Lamp Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Left Front Side Marker Lamp > Page 10128 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Left Front Side Marker Lamp (Headlamp And Dash) 2 Way Marker Lamp: Diagrams Left Front Side Marker Lamp (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY LAMP-SIDE MARKER-LEFT FRONT - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Left Front Side Marker Lamp (Headlamp And Dash) 2 Way > Page 10131 Marker Lamp: Diagrams Right Front Side Marker Lamp (Headlamp And Dash) 2 Way Connector - (HEADLAMP AND DASH) 2 WAY LAMP-SIDE MARKER-RIGHT FRONT - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Park Lamp Relay Parking Lamp Relay: Locations Park Lamp Relay Park Lamp Relay is located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Park Lamp Relay > Page 10137 Parking Lamp Relay: Locations Stop Lamp Inhibit Relay Stop Lamp Inhibit Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 10138 Parking Lamp Relay: Diagrams Connector (IN IPM) RELAY-PARK LAMP (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Description and Operation > Parking Lamp Relay - Description Parking Lamp Relay: Description and Operation Parking Lamp Relay - Description DESCRIPTION The park lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The park lamp relay is located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The park lamp relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Description and Operation > Parking Lamp Relay - Description > Page 10141 Parking Lamp Relay: Description and Operation Parking Lamp Relay - Operation OPERATION The park lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to the park lamps. Within the relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the park lamp relay include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a park lamp relay control circuit. The FCM controls park lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the park lamps through a park lamp relay output circuit and provides battery voltage to the park lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The park lamp relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Locations > Page 10146 Brake Lamp Relay: Diagrams Connector (IN PDC) RELAY-STOP LAMP ACTIVATION (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Description and Operation > Stop Lamp Inhibit Relay - Description Brake Lamp Relay: Description and Operation Stop Lamp Inhibit Relay - Description DESCRIPTION Vehicles equipped with an optional Electronic Stability Program (ESP)/Traction Control System (TCS) package have a stop lamp inhibit relay. The relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through four integral male spade-type terminals that extend from the relay base plate. The stop lamp inhibit relay is located in the Junction Block (JB) in the passenger compartment on the driver side cowl side inner panel below the end of the instrument panel. The stop lamp inhibit relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Brake Lamp Relay > Component Information > Description and Operation > Stop Lamp Inhibit Relay - Description > Page 10149 Brake Lamp Relay: Description and Operation Stop Lamp Inhibit Relay - Operation OPERATION The stop lamp inhibit relay is an electromechanical switch that uses a low current input from the Controller Antilock Brake (CAB) to interrupt a high current output from the brake lamp switch to the brake lamps. Within the relay is an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the stop lamp inhibit relay include: - Common Supply Terminal (30) - The common feed terminal is connected to the output of the brake lamp switch at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a control output of the CAB through a stop lamp inhibit relay control circuit. The CAB controls brake lamp operation by controlling a ground path through this circuit. - Coil Battery Terminal (86) - The coil battery terminal is connected to a fused ignition switch output (run-start) circuit at all times. - Normally Closed Terminal (87A) - The normally closed terminal is connected to the brake lamps through a brake lamp switch output circuit and provides battery voltage to the brake lamps whenever the relay is de-energized. The stop lamp inhibit relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Fog Lamp Relay is located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 10153 Fog/Driving Lamp Relay: Diagrams Connector (IN IPM) RELAY-FOG LAMP (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Description and Operation > Front Fog Lamp Relay - Description Fog/Driving Lamp Relay: Description and Operation Front Fog Lamp Relay - Description DESCRIPTION The front fog lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The front fog lamp relay is located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The front fog lamp relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Description and Operation > Front Fog Lamp Relay - Description > Page 10156 Fog/Driving Lamp Relay: Description and Operation Front Fog Lamp Relay - Operation OPERATION The front fog lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to the front fog lamps. Within the relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the front fog lamp relay include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a fog lamp relay control circuit. The FCM controls front fog lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the front fog lamps through a fog lamp relay output circuit and provides battery voltage to the front fog lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The front fog lamp relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Horn Relay is located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 10160 Horn Relay: Diagrams Connector (IN IPM) RELAY-HORN (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Park Lamp Relay Parking Lamp Relay: Locations Park Lamp Relay Park Lamp Relay is located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Park Lamp Relay > Page 10165 Parking Lamp Relay: Locations Stop Lamp Inhibit Relay Stop Lamp Inhibit Relay is located in the Power Distribution Center (PDC). Power Distribution Center (PDC) Power Distribution Center (PDC) is located in the left front corner of the engine compartment, just behind the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 10166 Parking Lamp Relay: Diagrams Connector (IN IPM) RELAY-PARK LAMP (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Description and Operation > Parking Lamp Relay - Description Parking Lamp Relay: Description and Operation Parking Lamp Relay - Description DESCRIPTION The park lamp relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The park lamp relay is located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The park lamp relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Description and Operation > Parking Lamp Relay - Description > Page 10169 Parking Lamp Relay: Description and Operation Parking Lamp Relay - Operation OPERATION The park lamp relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) (also referred to as the Integrated Power Module/IPM) to control a high current output to the park lamps. Within the relay are an electromagnetic coil, a movable contact and two fixed contact points. A resistor is connected in parallel with the coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the field of the relay coil collapses. The movable common supply contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This field draws the movable contact away from the normally closed contact, and holds it against the normally open contact. When the relay coil is de-energized, spring pressure returns the movable contact back against the normally closed contact. The inputs and outputs of the park lamp relay include: - Common Supply Terminal (30) - The common feed terminal is connected to a fused B(+) circuit at all times. - Coil Ground Terminal (85) - The coil ground terminal is connected to a fused B(+) circuit at all times. - Coil Battery Terminal (86) - The coil battery terminal is connected to a control output of the FCM through a park lamp relay control circuit. The FCM controls park lamp operation by controlling a ground path through this circuit. - Normally Open Terminal (87) - The normally open terminal is connected to the park lamps through a park lamp relay output circuit and provides battery voltage to the park lamps whenever the relay is energized. - Normally Closed Terminal (87A) - The normally closed terminal is not connected to any circuit in this application, but will have battery voltage present whenever the relay is de-energized. The park lamp relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Trailer Tow Left and Right Relays are located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Relay-Trailer Tow-Left Trailer Lighting Relay: Diagrams Relay-Trailer Tow-Left Connector (IN IPM) RELAY-TRAILER TOW-LEFT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Relay-Trailer Tow-Left > Page 10175 Trailer Lighting Relay: Diagrams Relay-Trailer Tow-Right Connector (IN IPM) RELAY-TRAILER TOW-RIGHT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Description and Operation Backup Lamp Switch: Description and Operation DESCRIPTION Vehicles with an electronic automatic transmission have a Transmission Range Sensor (TRS) that is used to perform several functions, including that of the backup lamp switch. The TRS is described in further detail elsewhere in this service information. Refer to the service and diagnostic information for the automatic transmission type installed in the vehicle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10183 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 10184 Brake Light Switch: Diagrams Connector - (INSTRUMENT PANEL) 6 WAY SWITCH-STOP LAMP - (INSTRUMENT PANEL) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description Brake Light Switch: Description and Operation Stop Lamp Switch - Description DESCRIPTION The brake lamp switch (2) is a three circuit, spring-loaded plunger actuated switch that is secured to the steering column support bracket under the instrument panel on the driver side of the vehicle. The molded plastic switch housing has an integral connector receptacle (1) containing six terminal pins and featuring a Connector Position Assurance (CPA) lock. The switch is connected to the vehicle electrical system through a dedicated take out of the instrument panel wire harness. The switch plunger (3) extends through a mounting collar (4) on one end of the switch housing. The plunger has a one time telescoping self-adjustment feature that is activated after the switch is installed by moving an adjustment release lever (5) on the opposite end of the switch housing clockwise, until it locks into a position that is horizontal and parallel to the connector receptacle. An installed brake lamp switch cannot be readjusted or repaired. If the switch is damaged, ineffective, or removed from its mounting position for any reason, it must be replaced with a new unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Stop Lamp Switch - Description > Page 10187 Brake Light Switch: Description and Operation Stop Lamp Switch - Operation OPERATION The brake lamp switch controls three independent circuits. These circuits are described as follows: - Brake Lamp Switch Circuit - A normally open brake lamp switch circuit receives a battery voltage input, and supplies this battery voltage to the brake lamps and the Controller Antilock Brake (CAB) on a brake lamp switch output circuit only when the brake pedal is depressed (brake lamp switch plunger released). - Brake Lamp Switch Signal Circuit - A normally closed brake lamp switch signal circuit receives a direct path to ground, and supplies this ground input to the Powertrain Control Module (PCM) on a brake lamp switch sense circuit only when the brake pedal is released (brake lamp switch plunger is depressed). - Speed Control Circuit - A normally closed speed control circuit receives a battery voltage input from the Powertrain Control Module on a speed control supply circuit, and supplies this battery voltage to the speed control servo solenoids (dump, vacuum, and vent) on a speed control brake switch output circuit only when the speed control system is turned ON and the brake pedal is released (brake lamp switch plunger is depressed). The components of the self-adjusting brake switch plunger consist of a two-piece telescoping plunger, a split plunger locking collar, and a release wedge. The release lever has a shaft with a wedge that spreads the plunger locking collar to an open or released position. After the switch is installed and the brake pedal is released, the plunger telescopes to the correct adjustment position. When the release lever is moved to the release position, the wedge is disengaged from the locking collar causing the collar to apply a clamping pressure to the two plunger halves, fixing the plunger length. The brake lamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Description and Operation > Page 10188 Brake Light Switch: Testing and Inspection BRAKE LAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. CAUTION: Do not remove the brake lamp switch from the mounting bracket. The self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 2. Disconnect the wire harness connector from the brake lamp switch. 3. Using an ohmmeter, perform the continuity tests at the terminal pins (1) in the brake lamp switch connector receptacle as shown in the Brake Lamp Switch Tests table. 4. If the switch fails any of the continuity tests, replace the ineffective brake lamp switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal Brake Light Switch: Service and Repair Stop Lamp Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Locate the brake lamp switch (1) near the support bracket on the lower steering column (3). 3. Disconnect the wire harness connector (5) from the brake lamp switch. 4. Rotate the brake lamp switch housing clockwise about 30 degrees to align the tabs on the switch locking collar with the keyed hole in the switch mounting bracket (4). 5. Pull the switch straight back from the keyed hole to remove it from the bracket. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. 6. Discard the removed brake lamp switch . Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair > Stop Lamp Switch - Removal > Page 10191 Brake Light Switch: Service and Repair Stop Lamp Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. CAUTION: The brake lamp switch self-adjusting switch plunger is a one time only feature. If the switch is removed from the mounting bracket, it MUST be replaced with a new switch. CAUTION: The brake lamp switch plunger MUST be in the fully extended position prior to releasing the brake pedal or setting the plunger length to ensure proper switch adjustment and operation. Do not manually press the plunger into the switch body prior to or during switch installation, and do not pull the brake pedal upward prior to setting the plunger length using the plunger adjustment release lever as described in the following procedure. 1. Depress and hold the brake pedal in the depressed position. 2. Align the tabs on the brake lamp switch locking collar with the keyed hole in the switch mounting bracket (4) on the lower steering column (3). 3. Insert the tabs on the brake lamp switch locking collar through the keyed hole in the switch mounting bracket until the switch housing (1) is firmly seated against the bracket. 4. Rotate the switch housing counterclockwise about 30 degrees to engage the tabs on the locking collar with the switch mounting bracket. CAUTION: Release, but do not pull up on the brake pedal before the switch plunger adjustment has been completed. 5. Release the brake pedal, but do not pull it upward. CAUTION: Be certain that the brake lamp switch plunger is in contact with the flag bracket on the brake pedal arm prior to rotating the plunger adjustment release lever. If the plunger is not contacting the flag bracket, depress and hold the brake pedal while manually pulling the plunger out from the switch body to the fully extended position. Then release the brake pedal, but do not pull it upward. 6. Rotate the plunger adjustment release lever (2) clockwise until it locks into place. The lever should be parallel to the brake lamp switch connector receptacle. This action will set the switch plunger length to a final adjustment position and cannot be undone. If not performed properly the first time, a new brake lamp switch must be installed. 7. Reconnect the wire harness connector (5) to the brake lamp switch. 8. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 10195 Combination Switch: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Multifunction Switch - Description Combination Switch: Description and Operation Multifunction Switch - Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Front Washer Control - The multi-function switch control knob provides a momentary front WASH position for front washer system operation. - Front Wiper Control - The multi-function switch control knob provides two continuous front wipe switch positions, LOW speed or HIGH speed; and an intermittent front wipe mode with five delay interval positions. Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Multifunction Switch - Description > Page 10198 Combination Switch: Description and Operation Multifunction Switch - Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control front washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control front wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Front Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the front WASH mode. The washer pump will continue to operate in the front washer mode until the control knob is released or for 10 continuous seconds, whichever occurs first. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front washer switch status messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The FCM responds by energizing or de-energizing the washer pump in the front washer mode. - Front Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous front wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front wiper switch status messages to the FCM over the CAN data bus. The FCM responds by energizing or de-energizing the wiper on/off and high/low relays in the Power Distribution Center (PDC) for front wiper system control. - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the FCM over the CAN data bus. The FCM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the FCM over the CAN data bus. The FCM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the FCM over the CAN data bus. The FCM energizes and flashes or de-energizes the selected left or right turn signal circuits. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Description and Operation > Page 10199 Combination Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the multi-function switch from the switch mounting housing on the steering column. See: Service and Repair/Multifunction Switch Removal. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Multifunction Switch - Removal Combination Switch: Service and Repair Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10202 8. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 9. Rotate the steering wheel far enough to access and remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 10. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10203 Combination Switch: Service and Repair Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Rotate the steering wheel far enough to install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. Be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10204 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation > Door Ajar Switch - Description Door Switch: Description and Operation Door Ajar Switch - Description DOOR This vehicle has four door ajar switches, one for each door. Each switch is concealed within and integral to its respective door latch unit. The switches are momentary leaf contact-type units that are actuated by the mechanisms internal to the door latch. A short pigtail wire and connector on each door latch connects the door ajar switch to the vehicle electrical system through its respective door wire harness. The door ajar switches cannot be adjusted or repaired and, if ineffective or damaged, the door latch unit must be replaced. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Latch/Service and Repair/Front Door Latch - Removal or See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Latch/Service and Repair/Rear Door Latch - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Description and Operation > Door Ajar Switch - Description > Page 10209 Door Switch: Description and Operation Door Ajar Switch - Operation DOOR The door ajar switches are actuated by the mechanisms internal to the door latch. When a door is closed and properly latched, its door ajar switch is an open circuit. When a door is open or only partially latched, the door ajar switch is a closed circuit. The rear door ajar switches are hard wired in series between a body ground and the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). On vehicles not equipped with the optional memory system, the front door ajar switches are also hard wired in series between ground and the EMIC. On vehicles equipped with the optional memory system each front door ajar switch is hard wired in series between ground and its respective driver or passenger Memory Mirror Module (MMM) located in the front door. The MMM then sends electronic door ajar switch status messages to the EMIC over the Controller Area Network (CAN) data bus. Both the EMIC and the MMM read the hard wired door ajar switch inputs through internal pull-ups, then use these inputs to control many electronic functions and features of the vehicle. The door ajar switches as well as the hard wired inputs and outputs of the switches may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 10213 Hazard Warning Switch: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 10217 Headlamp Dimmer Switch: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Multifunction Switch - Description Headlamp Dimmer Switch: Description and Operation Multifunction Switch - Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Front Washer Control - The multi-function switch control knob provides a momentary front WASH position for front washer system operation. - Front Wiper Control - The multi-function switch control knob provides two continuous front wipe switch positions, LOW speed or HIGH speed; and an intermittent front wipe mode with five delay interval positions. Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Multifunction Switch - Description > Page 10220 Headlamp Dimmer Switch: Description and Operation Multifunction Switch - Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control front washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control front wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Front Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the front WASH mode. The washer pump will continue to operate in the front washer mode until the control knob is released or for 10 continuous seconds, whichever occurs first. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front washer switch status messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The FCM responds by energizing or de-energizing the washer pump in the front washer mode. - Front Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous front wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front wiper switch status messages to the FCM over the CAN data bus. The FCM responds by energizing or de-energizing the wiper on/off and high/low relays in the Power Distribution Center (PDC) for front wiper system control. - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the FCM over the CAN data bus. The FCM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the FCM over the CAN data bus. The FCM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the FCM over the CAN data bus. The FCM energizes and flashes or de-energizes the selected left or right turn signal circuits. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Description and Operation > Page 10221 Headlamp Dimmer Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the multi-function switch from the switch mounting housing on the steering column. See: Combination Switch/Service and Repair/Multifunction Switch - Removal. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Multifunction Switch - Removal Headlamp Dimmer Switch: Service and Repair Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10224 8. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 9. Rotate the steering wheel far enough to access and remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 10. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10225 Headlamp Dimmer Switch: Service and Repair Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Rotate the steering wheel far enough to install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. Be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10226 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations > Page 10230 Headlamp Switch: Diagrams Connector - (INSTRUMENT PANEL) 10 WAY SWITCH-HEADLAMP - (INSTRUMENT PANEL) 10 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch - Description Headlamp Switch: Description and Operation Headlamp Switch - Description DESCRIPTION The headlamp switch (1) is located on the instrument panel, to the left of the steering column. Three different switches are used. The standard switch features a three-position rotary knob (4) for exterior lighting control and a thumbwheel (2) for panel lamps dimming and interior lighting control. An optional switch has a momentary push button (3) added for front fog lamp control. A second optional switch has the same thumbwheel and momentary push button, but has a fourth position added to the rotary knob for selecting the optional automatic headlamps feature. Each of these switches is constructed of molded plastic. The rotary knob is molded plastic and knurled around its circumference to ease operator control. The thumbwheel is also plastic and knurled. The optional front fog lamp push button is plastic with a smooth finish and an International Control and Display Symbol icon for Front Fog Light applied to it. The switch face plate is also labeled with graphics and icons to clearly identify the many functions of the rotary knob and thumbwheel. Three screws secure the switch to the back of the cluster bezel through integral mounting flanges that are molded to each side of the switch housing. The back of the switch housing has an integral connector receptacle containing terminal pins that connect the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. A panel dimmer controlled incandescent bulb soldered to the circuit board within the switch provides back lighting for visibility at night, but is not serviceable. The headlamp switch cannot be repaired and, if ineffective or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Headlamp Switch - Description > Page 10233 Headlamp Switch: Description and Operation Headlamp Switch - Operation OPERATION The headlamp switch uses two resistor multiplexed outputs to control the many functions and features it provides. The switch receives a clean ground from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a headlamp switch return circuit. It then provides outputs to the EMIC on a headlamp switch signal circuit to control exterior lighting functions, and on a panel lamps dimmer signal circuit to control panel dimmer and interior lighting functions. The switch illumination circuit receives a path to ground at all times through the left instrument panel ground circuit. The illumination level is controlled by a Pulse-Width Modulated (PWM) output received from the EMIC on a headlamp switch illumination control circuit. The EMIC controls this output based upon the dimmer signal select mux input from the headlamp switch. The headlamp switch operates as follows: - Front Fog Lamps Control - For vehicles so equipped, the fog lamp push button on the headlamp switch is depressed to activate or deactivate the optional front fog lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic fog lamp switch status messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The FCM responds by energizing or de-energizing the front fog lamp relay in the Power Distribution Center (PDC) and by sending an electronic message back to the EMIC to control the front fog lamp indicator. - Exterior Lighting Control - The rotary knob on the headlamp switch is rotated to a detent position to activate or deactivate the exterior lighting. The headlamp switch provides an output to the EMIC, and the EMIC responds by sending electronic exterior lighting switch status messages to the FCM over the CAN data bus. The FCM responds by energizing or de-energizing the park lamp relay in the PDC and the high or low beam headlamp circuits, and by sending an electronic message back to the EMIC to control the high beam indicator. The FCM also remembers which headlamp beams were last selected using the multi-function switch, and energizes those beams by default the next time the headlamps are turned ON. If the vehicle is equipped with optional automatic headlamps and the A (Automatic) position is selected, the EMIC also monitors an input from a sun load sensor on the instrument panel and, based upon the monitored ambient light levels, responds by automatically sending appropriate messages to the FCM to turn the exterior lighting ON or OFF while the ignition switch is in the ON position. - Interior Lighting Control - The thumbwheel on the headlamp switch is rotated to the dome DEFEAT, dome ON, PARADE mode, or one of the six panel dimmer detent positions to control the interior courtesy/dome and panel lamps. The headlamp switch provides an output to the EMIC, and the EMIC responds by providing the appropriate interior lighting control outputs through its internal courtesy lamp driver circuits, electronic dimming level messages to other modules over the CAN data bus, and the proper PWM outputs to control dimming levels through several panel dimmer illumination control driver circuits. The headlamp switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Description and Operation > Page 10234 Headlamp Switch: Testing and Inspection HEADLAMP SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the cluster bezel and the headlamp switch from the instrument panel as a unit. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Cluster Bezel - Removal. 2. Disconnect the wire harness connector from the back of the headlamp switch. 3. Using an ohmmeter, test the resistance or continuity between the terminals of the switch as shown in the Headlamp Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective headlamp switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch - Removal Headlamp Switch: Service and Repair Headlamp Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the cluster bezel (1) from the instrument panel See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Cluster Bezel - Removal. 3. Disconnect the wire harness connector from the back of the headlamp switch (2). 4. Place the cluster bezel face down on a suitable work surface. Be certain to take the proper precautions to protect the face of the bezel from cosmetic damage. 5. Remove the three screws (3) that secure the headlamp switch to the back of the cluster bezel. 6. Remove the headlamp switch from the cluster bezel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair > Headlamp Switch - Removal > Page 10237 Headlamp Switch: Service and Repair Headlamp Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Position the headlamp switch (2) to the back of the cluster bezel (1). 2. Install and tighten the three screws (3) that secure the headlamp switch to the cluster bezel. Tighten the screws to 2 Nm (17 in. lbs.). 3. Position the cluster bezel close enough to the instrument panel to reconnect the wire harness connector to the back of the headlamp switch. 4. Reinstall the cluster bezel onto the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair/Instrument Cluster Bezel - Installation. 5. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 10241 Horn Switch: Diagrams Connector - (STEERING WHEEL) 2 WAY SWITCH-HORN - (STEERING WHEEL) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Locations > Page 10242 Horn Switch: Testing and Inspection HORN SWITCH The most reliable, efficient and accurate means to diagnose the horn system requires the use of a scan tool and the proper diagnostic procedure information. For complete circuit diagrams, refer to the appropriate wiring information. WARNING: Disable the airbag system before attempting any steering wheel, steering column, seat belt tensioner, side airbag or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to follow these instructions may result in accidental airbag deployment and possible serious or fatal injury. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal Tail Light Bulb: Service and Repair Tail Stop Turn Lamp Bulb - Removal BULB - DODGE NOTE: The rear lamp unit contains four bulbs: side marker, tail/brake, tail/turn, and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the rear lamp unit (1) from the end of the quarter panel. See: Brake Lamp/Service and Repair/Tail Stop Turn Lamp - Removal. 3. Remove the three screws (3) that secure the socket plate (2) to the back of the rear lamp unit housing. 4. Remove the socket plate from the rear lamp. 5. Pull the base of the backup (1), tail/turn (2), tail/brake (3), or side marker (4) lamp bulb straight out of the appropriate socket in the socket plate (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal > Page 10248 Tail Light Bulb: Service and Repair Tail Stop Turn Lamp Bulb - Installation BULB - DODGE CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The rear lamp unit contains four bulbs: side marker, tail/brake, tail/turn, and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the backup (1), tail/turn (2), tail/brake (3), or side marker (4) lamp bulb with the appropriate socket in the socket plate (5). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket plate (2) and bulbs with the openings on the back of the rear lamp unit housing (1). 4. Insert the socket plate and bulbs straight into the housing until the plate is firmly seated. 5. Install and tighten the three screws (3) that secure the socket plate to the housing. Tighten the screws to 1 Nm (12 in. lbs.). 6. Reinstall the rear lamp unit onto the end of the quarter panel. See: Brake Lamp/Service and Repair/Tail Stop Turn Lamp - Installation. 7. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations Trailer Tow Left and Right Relays are located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Relay-Trailer Tow-Left Trailer Lighting Relay: Diagrams Relay-Trailer Tow-Left Connector (IN IPM) RELAY-TRAILER TOW-LEFT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Diagrams > Relay-Trailer Tow-Left > Page 10254 Trailer Lighting Relay: Diagrams Relay-Trailer Tow-Right Connector (IN IPM) RELAY-TRAILER TOW-RIGHT (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 10259 Combination Switch: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Multifunction Switch - Description Combination Switch: Description and Operation Multifunction Switch - Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Front Washer Control - The multi-function switch control knob provides a momentary front WASH position for front washer system operation. - Front Wiper Control - The multi-function switch control knob provides two continuous front wipe switch positions, LOW speed or HIGH speed; and an intermittent front wipe mode with five delay interval positions. Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Multifunction Switch - Description > Page 10262 Combination Switch: Description and Operation Multifunction Switch - Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control front washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control front wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Front Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the front WASH mode. The washer pump will continue to operate in the front washer mode until the control knob is released or for 10 continuous seconds, whichever occurs first. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front washer switch status messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The FCM responds by energizing or de-energizing the washer pump in the front washer mode. - Front Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous front wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front wiper switch status messages to the FCM over the CAN data bus. The FCM responds by energizing or de-energizing the wiper on/off and high/low relays in the Power Distribution Center (PDC) for front wiper system control. - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the FCM over the CAN data bus. The FCM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the FCM over the CAN data bus. The FCM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the FCM over the CAN data bus. The FCM energizes and flashes or de-energizes the selected left or right turn signal circuits. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Description and Operation > Page 10263 Combination Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the multi-function switch from the switch mounting housing on the steering column. See: Service and Repair/Multifunction Switch Removal. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Multifunction Switch - Removal Combination Switch: Service and Repair Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10266 8. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 9. Rotate the steering wheel far enough to access and remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 10. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10267 Combination Switch: Service and Repair Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Rotate the steering wheel far enough to install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. Be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10268 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Cancel Cam > Component Information > Description and Operation > Turn Signal Cancel Cam - Description Turn Signal Cancel Cam: Description and Operation Turn Signal Cancel Cam - Description DESCRIPTION The turn signal cancel cam (3) is concealed within the steering column. The turn signal cancel cam consists of two lobes on a molded plastic ring that is snapped into the lower hub of the clockspring rotor. The clockspring mechanism provides turn signal cancellation as well as a constant electrical connection between the horn switch, driver airbag, speed control switches, and remote radio switches on the steering wheel and the instrument panel wire harness on the steering column. The housing of the clockspring (2) is secured to the multi-function switch mounting housing on the steering column and remains stationary. The rotor of the clockspring, including the turn signal cancel cam lobes rotate with the steering wheel. The turn signal cancel cam is serviced as a unit with the clockspring and cannot be repaired. If ineffective or damaged, the entire clockspring unit must be replaced. See: Restraint Systems/Air Bag Systems/Clockspring Assembly / Spiral Cable/Service and Repair/Removal and Replacement/Clockspring - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Cancel Cam > Component Information > Description and Operation > Turn Signal Cancel Cam - Description > Page 10273 Turn Signal Cancel Cam: Description and Operation Turn Signal Cancel Cam - Operation OPERATION When the multi-function switch control stalk is moved to a latched turn signal position, a turn signal cancel actuator is extended from the inside surface of the switch housing toward the turn signal cancel cam. As the steering wheel is rotated to complete the turn, one of the two cam lobes will contact the actuator, automatically cancelling the turn signal event and releasing the latched multi-function switch control stalk to the neutral position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation > Turn Signal Indicator - Description Turn Signal Indicator: Description and Operation Turn Signal Indicator - Description DESCRIPTION Two turn signal indicators, one right and one left, are standard equipment on all instrument clusters. The turn signal indicators are located near the upper edge of the instrument cluster, the right one is between the speedometer and the tachometer, and the left one is between the speedometer and the minor gauge set. Each turn signal indicator consists of a stencil-like cutout of the International Control and Display Symbol icon for Turn Warning in the opaque layer of the instrument cluster overlay. The dark outer layer of the overlay prevents these indicators from being clearly visible when they are not illuminated. A green Light Emitting Diode (LED) behind each cutout in the opaque layer of the overlay causes each indicator to appear in green through the translucent outer layer of the overlay when it is illuminated from behind by the LED, which is soldered onto the instrument cluster electronic circuit board. The turn signal indicators are serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation > Turn Signal Indicator - Description > Page 10278 Turn Signal Indicator: Description and Operation Turn Signal Indicator - Operation OPERATION The turn signal indicators give an indication to the vehicle operator that a turn signal (left or right indicator flashing) or the hazard warning (both left and right indicators flashing) have been selected and are operating. These indicators are controlled by transistors on the instrument cluster electronic circuit board based upon cluster programming, a hardwired multiplex input received by the cluster from the turn signal and hazard warning switch circuitry of the multifunction switch on the turn/hazard switch mux circuit, and electronic messages received from the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. Each turn signal indicator Light Emitting Diode (LED) is completely controlled by the instrument cluster logic circuit. This logic allows the indicator to operate whenever the instrument cluster receives a battery current input on the fused B(+) circuit. Therefore, each LED can be illuminated regardless of the ignition switch position. The LED only illuminates when it is provided a path to ground by the instrument cluster transistor. The instrument cluster turns on the turn signal indicators for the following reasons: - Turn Signal-On Input - Each time the cluster detects a turn signal-ON input from the turn signal switch circuitry of the multifunction switch on the turn/hazard switch mux circuit, it sends the appropriate electronic turn signal switch status messages to the FCM over the CAN data bus. The FCM responds to these messages by controlling a battery voltage output and the flash rate for either the right or left turn signal lamps. The FCM also sends the appropriate electronic messages back to the cluster to control the flash rate of the turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the cluster electronic circuit board that emulates the sound emitted by a conventional turn signal flasher. The turn signal indicators continue to flash on and off until the cluster receives a turn signal-off input from the multifunction switch, or until the ignition switch is turned to the OFF position, whichever occurs first. - Hazard Warning-On Input - Each time the cluster detects a hazard warning-ON input from the hazard warning switch circuitry of the multifunction switch on the turn/hazard switch mux circuit, it sends the appropriate electronic hazard switch status messages to the FCM over the CAN data bus. The FCM responds to these messages by controlling a battery voltage output and the flash rate for each of the right and left turn signal lamps. The FCM also sends the appropriate electronic messages back to the cluster to control the flash rate of the turn signal indicators, as well as to control the click rate of an electromechanical relay soldered onto the cluster electronic circuit board that emulates the sound emitted by a conventional hazard warning flasher. The turn signal indicators continue to flash on and off until the cluster receives a hazard warning-off input from the multifunction switch. - Lamp Out Mode - If the FCM detects an ineffective turn signal lamp or circuit, it increases the flash rate for the remaining operative turn signals and sends an electronic message to the instrument cluster. The instrument cluster then increases the flash rate of the turn signal indicators and the click rate of the electromechanical relay to provide an indication of the problem to the vehicle operator. - Self Test - Each time the cluster is put through the self test, the turn signal indicators turn on, then off again during the bulb check portion of the test to confirm the functionality of each LED and the cluster control circuitry. The instrument cluster, also known as the Cab Compartment Node CCN) continually monitors the multifunction switch and electronic messages from the FCM to determine the proper turn signal and hazard warning indicator operation. For further diagnosis of the turn signal indicators or the instrument cluster circuitry that controls the indicators, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the turn signal and hazard warning system, the multifunction switch, the FCM, the CCN, the CAN data bus or the electronic communication related to turn signal indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal Turn Signal Bulb: Service and Repair Tail Stop Turn Lamp Bulb - Removal BULB - DODGE NOTE: The rear lamp unit contains four bulbs: side marker, tail/brake, tail/turn, and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the rear lamp unit (1) from the end of the quarter panel. See: Brake Lamp/Service and Repair/Tail Stop Turn Lamp - Removal. 3. Remove the three screws (3) that secure the socket plate (2) to the back of the rear lamp unit housing. 4. Remove the socket plate from the rear lamp. 5. Pull the base of the backup (1), tail/turn (2), tail/brake (3), or side marker (4) lamp bulb straight out of the appropriate socket in the socket plate (5). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal > Page 10284 Turn Signal Bulb: Service and Repair Tail Stop Turn Lamp Bulb - Installation BULB - DODGE CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The rear lamp unit contains four bulbs: side marker, tail/brake, tail/turn, and backup. The service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the backup (1), tail/turn (2), tail/brake (3), or side marker (4) lamp bulb with the appropriate socket in the socket plate (5). 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket plate (2) and bulbs with the openings on the back of the rear lamp unit housing (1). 4. Insert the socket plate and bulbs straight into the housing until the plate is firmly seated. 5. Install and tighten the three screws (3) that secure the socket plate to the housing. Tighten the screws to 1 Nm (12 in. lbs.). 6. Reinstall the rear lamp unit onto the end of the quarter panel. See: Brake Lamp/Service and Repair/Tail Stop Turn Lamp - Installation. 7. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal > Page 10285 Turn Signal Bulb: Service and Repair Front Lamp Unit Bulb - Removal BULB - PARK/TURN SIGNAL OR SIDE MARKER NOTE: The front lamp unit contains three bulbs: headlamp (3), park/turn signal (2), and side marker (4). Except for the headlamp bulb, the service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the front lamp unit (1) from the front fender, but do not disconnect the headlamp and dash wiring from the back of the lamp housing. See: Service and Repair/Front Lamp Unit - Removal. 3. Disconnect the headlamp and dash wire harness connector from the appropriate park/turn signal (2) or side marker (4) bulb socket on the back of the front lamp unit housing. 4. Firmly grasp the park/turn signal or side marker bulb socket and rotate it counterclockwise about 30 degrees to unlock it. 5. Pull the socket and bulb straight out from the keyed opening in the housing. 6. Pull the base of the bulb straight out of the socket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Tail Stop Turn Lamp Bulb - Removal > Page 10286 Turn Signal Bulb: Service and Repair Front Lamp Unit Bulb - Installation BULB - PARK/TURN SIGNAL OR SIDE MARKER CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: The front lamp unit contains three bulbs: headlamp (3), park/turn signal (2), and side marker (4). Except for the headlamp bulb, the service procedures for each bulb are the same, only the bulb sizes and types may differ. 1. Align the base of the bulb with the appropriate park/turn signal (2) or side marker (4) bulb socket. 2. Push the bulb straight into the socket until the base is firmly seated. 3. Align the socket and bulb with the keyed opening on the back of the front lamp unit (1) housing. 4. Insert the socket and bulb into the housing until the socket is firmly seated. 5. Rotate the socket clockwise about 30 degrees to lock it into place. 6. Reconnect the headlamp and dash wire harness connector to the appropriate park/turn signal or side marker bulb socket. 7. Reinstall the front lamp unit into the front fender. See: Service and Repair/Front Lamp Unit - Installation. 8. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > Left Vanity Lamp Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Locations > Left Vanity Lamp > Page 10291 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Left Vanity Lamp (Body) 2 Way Vanity Lamp: Diagrams Left Vanity Lamp (Body) 2 Way Connector - (BODY) 2 WAY LAMP-VANITY-LEFT - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Left Vanity Lamp (Body) 2 Way > Page 10294 Vanity Lamp: Diagrams Right Vanity Lamp (Body) 2 Way Connector - (BODY) 2 WAY LAMP-VANITY-RIGHT - (BODY) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Service and Repair > Vanity Lamp - Removal Vanity Lamp: Service and Repair Vanity Lamp - Removal REMOVAL NOTE: Vehicles equipped with optional vanity lamps have a mirror with a single lamp that is integral to each sun visor. Each lamp is independently controlled by an integral switch that is automatically actuated by the mirror cover. The bulb types and service procedures are identical for each of these lamps. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Insert a small flat-bladed screwdriver on either side near the top or the bottom between the vanity lamp lens (2) and the lamp housing of the sun visor (1). 3. Carefully pry the lens outward until it unsnaps from the lamp housing. 4. Using small needle-nose pliers, carefully grasp the bulb (2) and pull the base out of the lamp socket. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Service and Repair > Vanity Lamp - Removal > Page 10297 Vanity Lamp: Service and Repair Vanity Lamp - Installation INSTALLATION CAUTION: Always use the correct bulb size and type for replacement. An incorrect bulb size or type may overheat and cause damage to the lamp, the socket or the lamp wiring. NOTE: Vehicles equipped with optional vanity lamps have a mirror with a single lamp that is integral to each sun visor. Each lamp is independently controlled by an integral switch that is automatically actuated by the mirror cover. The bulb types and service procedures are identical for each of these lamps. 1. Using small needle-nose pliers, carefully grasp the vanity lamp bulb (2) and align the base of the bulb with the socket in the lamp housing of the sun visor (1). 2. Push the bulb straight into the socket until the base is fully seated. 3. Insert one tab on the top or the bottom of the lens (2) into the appropriate slot at the top or bottom of the lamp housing. 4. Flex the lens far enough to engage the loose tab into its slot in the lamp housing. 5. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Window Defogger Relay is located in the Junction Block (JB). Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Locations > Page 10303 Heated Glass Element Relay: Diagrams Connector (IN JB) RELAY-REAR WINDOW DEFOGGER (IN JB) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Description and Operation > Rear Defogger Relay - Description Heated Glass Element Relay: Description and Operation Rear Defogger Relay - Description DESCRIPTION The rear window defogger (EBL) relay (1) is an International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The EBL relay is a electromechanical device that switches battery current through a fuse in the power distribution center (PDC) to the rear window defogger grid and to the outside mirror heating grids. The EBL relay is energized when the relay coil is provided a ground path by the rear window defogger relay control in the front control module (FCM). The EBL relay is located in the junction block (JB) in the passenger compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Description and Operation > Rear Defogger Relay - Description > Page 10306 Heated Glass Element Relay: Description and Operation Rear Defogger Relay - Operation OPERATION The ISO-standard rear window defogger (EBL) relay is an electromechanical switch that uses a low current input controlled by the front control module (FCM) to control the high current output to the rear window defogger grid lines. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the rear window defogger grid lines. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The EBL relay terminals are connected to the vehicle electrical system through a receptacle in the junction block (JB). The inputs and outputs of the EBL relay include: - The common feed terminal (30) receives fused battery current at all times. - The coil ground terminal (85) receives a ground through the EBL relay control circuit only when the front control module (FCM) electronically pulls the circuit to ground. - The coil battery terminal (86) receives fused battery current through an ignition switch output circuit only when the ignition switch is in RUN. - The normally open terminal (87) provides battery current to the rear window defogger grid lines through the EBL relay output circuit only when the EBL relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the EBL relay coil is de-energized. The EBL relay cannot be adjusted or repaired and must be replaced if inoperative or damaged. See Wiring Information for diagnosis and testing of the EBL relay and for complete rear window defogger (EBL) wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Service and Repair > Rear Defogger Relay - Removal Heated Glass Element Relay: Service and Repair Rear Defogger Relay - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the trim cover from the cowl (2) on the driver side of the vehicle. 3. Locate the junction block (JB) (1). NOTE: Refer to the fuse and relay map on the inside of the JB cover for EBL relay location. 4. Remove the EBL relay from the JB. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component Information > Service and Repair > Rear Defogger Relay - Removal > Page 10309 Heated Glass Element Relay: Service and Repair Rear Defogger Relay - Installation INSTALLATION NOTE: Refer to the fuse and relay map on the inside of the junction block (JB) cover for EBL relay location. 1. Position the EBL relay to the JB (1). 2. Align the EBL relay terminals with the terminal cavities in the JB receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the trim cover onto the driver side cowl (2).See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Description and Operation/Junction Block - Description. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Description DESCRIPTION The switch for the rear window defogger (EBL) system (2) is integrated into the A/C-heater control (1) located in the center of the instrument panel. When the rear window defogger switch is activated, the timing circuit integral to the A/C-heater control operates the rear window defogger (EBL) relay. An amber indicator (3) in the rear window defogger switch will illuminate to indicate when the EBL system is turned on. When the EBL relay is activated, current is directed to the rear window defogger grid lines and when equipped, to the heated outside rear view mirrors. The grid lines heat the window and mirror glass to help clear the surfaces of fog or frost. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description > Page 10314 Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Operation OPERATION An amber indicator in the rear window defogger switch will illuminate when the rear window defogger switch is activated. When the switch is activated, the A/C-heater control requests the front control module (FCM) to operated the rear window defogger (EBL) relay via the controller area network (CAN) B bus. The EBL relay controls the current flow to the heating grid of the rear window and when equipped, the heated outside rear view mirrors. NOTE: The EBL system turns off automatically after approximately 15 minutes of initial operation. Each following activation cycle of the EBL system will last approximately 10 minutes. The EBL system will be automatically turned off after an initial programmed time interval of about 15 minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 10 minutes. The EBL system will also turn off if the ignition switch is turned to any position other than RUN or by manually pressing the rear window defogger switch a second time. The rear window defogger switch and indicator lamp cannot be adjusted or repaired and the A/C-heater control must be replaced if inoperative or damaged See: Heating and Air Conditioning/Control Assembly/Service and Repair/A/C and Heater Control - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations Heated Glass Element Relay: Locations Window Defogger Relay is located in the Junction Block (JB). Junction Block Junction Block (JB) is concealed behind the left outboard end of the instrument panel cover. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Locations > Page 10319 Heated Glass Element Relay: Diagrams Connector (IN JB) RELAY-REAR WINDOW DEFOGGER (IN JB) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Description and Operation > Rear Defogger Relay - Description Heated Glass Element Relay: Description and Operation Rear Defogger Relay - Description DESCRIPTION The rear window defogger (EBL) relay (1) is an International Standards Organization (ISO)-type relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal functions and patterns (2). The EBL relay is a electromechanical device that switches battery current through a fuse in the power distribution center (PDC) to the rear window defogger grid and to the outside mirror heating grids. The EBL relay is energized when the relay coil is provided a ground path by the rear window defogger relay control in the front control module (FCM). The EBL relay is located in the junction block (JB) in the passenger compartment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Description and Operation > Rear Defogger Relay - Description > Page 10322 Heated Glass Element Relay: Description and Operation Rear Defogger Relay - Operation OPERATION The ISO-standard rear window defogger (EBL) relay is an electromechanical switch that uses a low current input controlled by the front control module (FCM) to control the high current output to the rear window defogger grid lines. The movable, common feed relay contact is held against the fixed, normally closed relay contact by spring pressure. When the electromagnetic relay coil is energized, it draws the movable common feed relay contact away from the fixed, normally closed relay contact and, holds it against the fixed, normally open relay contact. This action allows high current to flow to the rear window defogger grid lines. When the relay coil is de-energized, spring pressure returns the movable relay contact back against the fixed, normally closed contact point. The resistor or diode is connected in parallel with the relay coil, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The EBL relay terminals are connected to the vehicle electrical system through a receptacle in the junction block (JB). The inputs and outputs of the EBL relay include: - The common feed terminal (30) receives fused battery current at all times. - The coil ground terminal (85) receives a ground through the EBL relay control circuit only when the front control module (FCM) electronically pulls the circuit to ground. - The coil battery terminal (86) receives fused battery current through an ignition switch output circuit only when the ignition switch is in RUN. - The normally open terminal (87) provides battery current to the rear window defogger grid lines through the EBL relay output circuit only when the EBL relay coil is energized. - The normally closed terminal (87A) is not connected to any circuit in this application, but provides a battery current output only when the EBL relay coil is de-energized. The EBL relay cannot be adjusted or repaired and must be replaced if inoperative or damaged. See Wiring Information for diagnosis and testing of the EBL relay and for complete rear window defogger (EBL) wiring diagrams. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Service and Repair > Rear Defogger Relay - Removal Heated Glass Element Relay: Service and Repair Rear Defogger Relay - Removal REMOVAL 1. Disconnect and isolate the negative battery cable. 2. Remove the trim cover from the cowl (2) on the driver side of the vehicle. 3. Locate the junction block (JB) (1). NOTE: Refer to the fuse and relay map on the inside of the JB cover for EBL relay location. 4. Remove the EBL relay from the JB. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay > Component Information > Service and Repair > Rear Defogger Relay - Removal > Page 10325 Heated Glass Element Relay: Service and Repair Rear Defogger Relay - Installation INSTALLATION NOTE: Refer to the fuse and relay map on the inside of the junction block (JB) cover for EBL relay location. 1. Position the EBL relay to the JB (1). 2. Align the EBL relay terminals with the terminal cavities in the JB receptacle and push down firmly on the relay until the terminals are fully seated. 3. Install the trim cover onto the driver side cowl (2).See: Maintenance/Fuses and Circuit Breakers/Fuse Block/Description and Operation/Junction Block - Description. 4. Reconnect the negative battery cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Description DESCRIPTION The switch for the rear window defogger (EBL) system (2) is integrated into the A/C-heater control (1) located in the center of the instrument panel. When the rear window defogger switch is activated, the timing circuit integral to the A/C-heater control operates the rear window defogger (EBL) relay. An amber indicator (3) in the rear window defogger switch will illuminate to indicate when the EBL system is turned on. When the EBL relay is activated, current is directed to the rear window defogger grid lines and when equipped, to the heated outside rear view mirrors. The grid lines heat the window and mirror glass to help clear the surfaces of fog or frost. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Description and Operation > Rear Defogger Switch - Description > Page 10331 Heated Glass Element Switch: Description and Operation Rear Defogger Switch - Operation OPERATION An amber indicator in the rear window defogger switch will illuminate when the rear window defogger switch is activated. When the switch is activated, the A/C-heater control requests the front control module (FCM) to operated the rear window defogger (EBL) relay via the controller area network (CAN) B bus. The EBL relay controls the current flow to the heating grid of the rear window and when equipped, the heated outside rear view mirrors. NOTE: The EBL system turns off automatically after approximately 15 minutes of initial operation. Each following activation cycle of the EBL system will last approximately 10 minutes. The EBL system will be automatically turned off after an initial programmed time interval of about 15 minutes as long as the ignition switch is in RUN. After the initial time interval has expired, if the rear window defogger switch is pressed to ON again during the same ignition cycle, the EBL system will automatically turn off after about 10 minutes. The EBL system will also turn off if the ignition switch is turned to any position other than RUN or by manually pressing the rear window defogger switch a second time. The rear window defogger switch and indicator lamp cannot be adjusted or repaired and the A/C-heater control must be replaced if inoperative or damaged See: Heating and Air Conditioning/Control Assembly/Service and Repair/A/C and Heater Control - Removal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 10336 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 10337 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 10338 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Left Rear Door) 6 Way Power Window Switch: Diagrams Left Rear Power Window Switch (Left Rear Door) 6 Way Connector - (LEFT REAR DOOR) 6 WAY SWITCH-POWER WINDOW-LEFT REAR - (LEFT REAR DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Left Rear Door) 6 Way > Page 10341 Power Window Switch: Diagrams Right Rear Power Window Switch (Right Rear Door) 6 Way Connector - (RIGHT REAR DOOR) 6 WAY SWITCH-POWER WINDOW-RIGHT REAR - (RIGHT REAR DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Left Rear Door) 6 Way > Page 10342 Power Window Switch: Diagrams Driver Window/Door Lock Switch C1 (Left Front Door) 8 Way Connector C1 - (LEFT FRONT DOOR) 8 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (LEFT FRONT DOOR) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Left Rear Door) 6 Way > Page 10343 Power Window Switch: Diagrams Driver Window/Door Lock Switch C2 (Left Front Door) 6 Way Connector C2 - (LEFT FRONT DOOR) 6 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (LEFT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Left Rear Door) 6 Way > Page 10344 Power Window Switch: Diagrams Passenger Window/Door Lock Switch (Right Front Door) 6 Way Connector - (RIGHT FRONT DOOR) 6 WAY SWITCH-WINDOW/DOOR LOCK-PASSENGER - (RIGHT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 10345 Power Window Switch: Testing and Inspection POWER WINDOW SWITCH The front door power window switches are included in the window/lock switchSee: Body and Frame/Locks/Power Locks/Power Door Lock Switch/Testing and Inspection. The Light-Emitting Diode (LED) illumination lamps for all of the power window switch knobs receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in the power window switch and the power windows are inoperative, . See: Windows/Testing and Inspection/Symptom Related Diagnostic Procedures If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. 1. Check the fuse and the circuit breaker. If OK, go to 2. If not OK, replace the fuse or circuit breaker. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fuse in the Integrated Power Module (IPM). If OK, turn the ignition switch to the OFF position and go to 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch from the door trim panel. Unplug the wire harness connector from the switch. 4. Test the power window switch continuity. See the Power Window Switch Continuity chart to determine if the continuity is correct in the Neutral, Up and Down switch positions. If OK, See: Windows/Testing and Inspection/Symptom Related Diagnostic Procedures. If not OK, replace the inoperative switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal Power Window Switch: Service and Repair Power Window Switch - Removal REMOVAL The driver and front passenger side power window switch is included in the window/lock switch. See: Body and Frame/Locks/Power Locks/Power Door Lock Switch/Service and Repair/Power Lock Switch - Removal for the service procedures. 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Removal. 3. Remove switch from door trim panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal > Page 10348 Power Window Switch: Service and Repair Power Window Switch - Installation INSTALLATION The driver and front passenger side power window switch is included in the window/lock switch. See: Body and Frame/Locks/Power Locks/Power Door Lock Switch/Service and Repair/Power Lock Switch - Installation. 1. Install the switch to the door trim panel. 2. Install the door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Installation. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor > Component Information > Testing and Inspection Front Door Window Motor: Testing and Inspection WINDOW MOTOR For complete circuit diagrams, refer to the appropriate wiring information. 1. Disconnect and isolate the battery negative cable. Remove the trim panel from the door with the inoperative power window. 2. Unplug the power window motor wire harness connector. Apply 12 volts across the motor terminals to check its operation in one direction. Reverse the connections across the motor terminals to check the operation in the other direction. If the window is in the full up or full down position, the motor will not operate in that direction by design. If OK, repair the circuits from the power window motor to the power window switch as required. If not OK, replace the inoperative motor. 3. If the motor operates in both directions, check the operation of the window glass and lift mechanism through its complete up and down travel. There should be no binding or sticking of the window glass or lift mechanism through the entire travel range. If not OK, check the window glass, tracks, and regulator for sticking, binding, or improper adjustment. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 10358 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 10359 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Locations > Left Rear Power Window Switch > Page 10360 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Left Rear Door) 6 Way Power Window Switch: Diagrams Left Rear Power Window Switch (Left Rear Door) 6 Way Connector - (LEFT REAR DOOR) 6 WAY SWITCH-POWER WINDOW-LEFT REAR - (LEFT REAR DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Left Rear Door) 6 Way > Page 10363 Power Window Switch: Diagrams Right Rear Power Window Switch (Right Rear Door) 6 Way Connector - (RIGHT REAR DOOR) 6 WAY SWITCH-POWER WINDOW-RIGHT REAR - (RIGHT REAR DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Left Rear Door) 6 Way > Page 10364 Power Window Switch: Diagrams Driver Window/Door Lock Switch C1 (Left Front Door) 8 Way Connector C1 - (LEFT FRONT DOOR) 8 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (LEFT FRONT DOOR) 8 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Left Rear Door) 6 Way > Page 10365 Power Window Switch: Diagrams Driver Window/Door Lock Switch C2 (Left Front Door) 6 Way Connector C2 - (LEFT FRONT DOOR) 6 WAY SWITCH-WINDOW/DOOR LOCK-DRIVER - (LEFT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Left Rear Power Window Switch (Left Rear Door) 6 Way > Page 10366 Power Window Switch: Diagrams Passenger Window/Door Lock Switch (Right Front Door) 6 Way Connector - (RIGHT FRONT DOOR) 6 WAY SWITCH-WINDOW/DOOR LOCK-PASSENGER - (RIGHT FRONT DOOR) 6 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 10367 Power Window Switch: Testing and Inspection POWER WINDOW SWITCH The front door power window switches are included in the window/lock switchSee: Body and Frame/Locks/Power Locks/Power Door Lock Switch/Testing and Inspection. The Light-Emitting Diode (LED) illumination lamps for all of the power window switch knobs receive battery current through the power window circuit breaker in the junction block. If all of the LEDs are inoperative in the power window switch and the power windows are inoperative, . See: Testing and Inspection/Symptom Related Diagnostic Procedures If the power windows operate, but any or all of the LEDs are inoperative, the power window and lock switch units with the inoperative LED(s) must be replaced. For complete circuit diagrams, refer to the appropriate wiring information. 1. Check the fuse and the circuit breaker. If OK, go to 2. If not OK, replace the fuse or circuit breaker. 2. Turn the ignition switch to the ON position. Check for battery voltage at the fuse in the Integrated Power Module (IPM). If OK, turn the ignition switch to the OFF position and go to 3. If not OK, check circuit breaker and repair the circuit to the ignition switch as required. 3. Disconnect and isolate the battery negative cable. Remove the power window switch from the door trim panel. Unplug the wire harness connector from the switch. 4. Test the power window switch continuity. See the Power Window Switch Continuity chart to determine if the continuity is correct in the Neutral, Up and Down switch positions. If OK, See: Testing and Inspection/Symptom Related Diagnostic Procedures. If not OK, replace the inoperative switch. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal Power Window Switch: Service and Repair Power Window Switch - Removal REMOVAL The driver and front passenger side power window switch is included in the window/lock switch. See: Body and Frame/Locks/Power Locks/Power Door Lock Switch/Service and Repair/Power Lock Switch - Removal for the service procedures. 1. Disconnect and isolate the battery negative cable. 2. Remove the door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Removal. 3. Remove switch from door trim panel. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch - Removal > Page 10370 Power Window Switch: Service and Repair Power Window Switch - Installation INSTALLATION The driver and front passenger side power window switch is included in the window/lock switch. See: Body and Frame/Locks/Power Locks/Power Door Lock Switch/Service and Repair/Power Lock Switch - Installation. 1. Install the switch to the door trim panel. 2. Install the door trim panel See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Rear Door Trim Panel - Installation. 3. Connect the battery negative cable. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal Liftgate Window Glass: Service and Repair Liftgate Backlite - Removal REMOVAL NOTE: Windshield removal shown, backlite similar. 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Windshield/Service Precautions 2. Remove liftgate trim panels. See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal 3. Remove the center stop light. . See: Lighting and Horns/Center Mounted Brake Lamp/Service and Repair/Center Mounted Brake Lamp - Removal 4. Remove rear window wiper arm, if equipped. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Removal 5. Disconnect the heated backlite electrical connectors, if equipped. 6. Using a windshield cut-out wire or other suitable tool, separate the adhesive. 7. Carefully remove backlite. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal > Page 10376 Liftgate Window Glass: Service and Repair Liftgate Backlite - Installation INSTALLATION WARNING: Allow the urethane at least 24 hours to cure before returning the vehicle to use. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing backlite to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. NOTE: The backlite fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Support spacers should be replaced with new parts. Replace any missing or damaged spacers around the perimeter of the liftgate opening. Glass Preparation - Installing A Previously Installed Backlite 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Windshield/Service Precautions 2. Level old bead of backlite adhesive (3) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. 3. Apply four new spacers (1) to the liftgate frame and place them 55 mm in from the window opening; 70 mm from the upper edge and 150 mm from the lower edge. 4. Install the lower spacers (2) to the backlite approximately 36 cm (1.0 in) from each side of the glass. NOTE: Remove the lower spacers 2 hours after installation of the glass. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal > Page 10377 5. Position backlite in center of liftgate opening and resting on the side and lower spacers. 6. Apply adhesive tape strips (1) around the perimeter of the liftgate opening to aid in installation. NOTE: Windshield installation shown, backlite similar. 7. Verify the backlite gap is parallel to with the liftgate opening. 8. Cut tape with a sharp knife and remove backlite. NOTE: Typical primer installation shown. 9. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 10. Using a flash light, verify that glass primer is without damage. 11. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal > Page 10378 12. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2). 13. Allow primer to air dry for at least 10 minutes. 14. Using a flash light, verify that glass primer is without damage. Glass Preparation - Installing A New Backlite 1. Apply four new spacers (1) to the liftgate frame and place them 55 mm in from the window opening; 70 mm from the upper edge and 150 mm from the lower edge. 2. Install the lower spacers (2) to the backlite approximately 36 cm (1.0 in) from each side of the glass. NOTE: Remove the lower spacers 2 hours after installation of the glass. 3. Position backlite in center of liftgate opening and resting on the side and lower spacers. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal > Page 10379 4. Apply adhesive tape strips (1) around the perimeter of the liftgate opening to aid in installation. NOTE: Windshield installation shown, backlite similar. 5. Verify the backlite gap is parallel to with the liftgate opening. 6. Cut tape with a sharp knife and remove backlite. NOTE: Typical primer installation shown. 7. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 8. Apply primer to gluing surface at backlite seal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal > Page 10380 9. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2). 10. Allow primer to air dry for at least 10 minutes. 11. Using a flash light, verify that glass primer is without damage. Liftgate Opening Preparation NOTE: Windshield opening shown, liftgate opening similar. 1. Clean and vacuum liftgate opening. 2. Level old bead of liftgate opening adhesive (1) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal > Page 10381 NOTE: Windshield opening shown, liftgate opening similar. 3. Clean and dry area of liftgate opening to be re-glued with a suitable glass preparation solvent and rag. 4. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. 5. Allow primer to air dry for at least 10 minutes. Backlite Installation 1. Apply bead of adhesive (1) with a triangular nozzle directly to the backlite seal starting at bottom in center of the backlite. CAUTION: Always apply bead of adhesive to the backlite. Always install the backlite within 5 minutes after applying adhesive. 2. Bead dimensions should be approximately 9.5 mm wide (1) by 12.7 mm in height (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component Information > Service and Repair > Liftgate Backlite - Removal > Page 10382 3. Allow end of adhesive bead (1) to run out parallel to the start of the bead and smooth ends flush. 4. Lift backlite into place in the center of the liftgate opening and use the tape as a guide to aid installation of the backlite into the center of the cutout. 5. Carefully lay down the backlite and press on. CAUTION: It is no longer possible to move the backlite after installation. The backlite should never be pressed into place by more than one person, because the backlite can break if pressed simultaneously on both sides. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing backlite to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. 6. Install the rear wiper arm, if equipped. See: Wiper and Washer Systems/Wiper Arm/Service and Repair/Wiper Arm - Installation 7. Install the liftgate trim panels. 8. Install the center stop light, . See: Lighting and Horns/Center Mounted Brake Lamp/Service and Repair/Center Mounted Brake Lamp Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Quarter Glass - Removal Quarter Window Glass: Service and Repair Quarter Glass - Removal REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions See: Windshield/Service Precautions. 2. Remove quarter panel trim See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Removal. NOTE: Windshield removal shown, quarter glass similar. 3. Using a windshield cut-out wire (4) or other suitable tool, separate the adhesive (2). 4. Release the tabs (2) and the tabs on the alignment pin (4) and carefully remove the quarter glass. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Quarter Glass - Removal > Page 10387 Quarter Window Glass: Service and Repair Quarter Glass - Installation INSTALLATION WARNING: Allow the urethane at least 24 hours to cure before returning the vehicle to use. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing quarter glass to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. NOTE: The quarter glass fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Glass Preparation - Installing A Previously Installed Quarter Glass 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Windshield/Service Precautions 2. Level old bead of quarter glass adhesive (3) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. NOTE: Typical primer installation shown. 3. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 4. Using a flash light, verify that glass primer is without damage. 5. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Quarter Glass - Removal > Page 10388 6. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (3). NOTE: Make sure the primer does not touch the locating pins and tabs (2, 4). 7. Allow primer to air dry for at least 10 minutes. 8. Using a flash light, verify that glass primer is without damage. Glass Preparation - Installing A New Quarter Glass NOTE: Typical primer installation shown. 1. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 2. Apply primer to gluing surface at quarter glass seal. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Quarter Glass - Removal > Page 10389 3. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (3). NOTE: Make sure the primer does not touch the locating pins and tabs (2, 4). 4. Allow primer to air dry for at least 10 minutes. 5. Using a flash light, verify that glass primer is without damage. Quarter Glass Opening Preparation NOTE: Windshield opening shown, quarter glass opening similar. 1. Clean and vacuum quarter glass opening. 2. Level old bead of quarter glass opening adhesive (1) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Quarter Glass - Removal > Page 10390 NOTE: Windshield opening shown, quarter glass opening similar. 3. Clean and dry area of quarter glass opening to be re-glued with a suitable glass preparation solvent and rag. 4. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. NOTE: Make sure the primer does not touch the locating pins and tabs. 5. Allow primer to air dry for at least 10 minutes. Quarter Glass Installation 1. Apply bead of adhesive (1) with a triangular nozzle directly to the quarter glass seal starting at bottom in center of the quarter glass. CAUTION: Always apply bead of adhesive to the quarter glass. Always install the quarter glass within 5 minutes after applying adhesive. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Service and Repair > Quarter Glass - Removal > Page 10391 2. Bead dimensions should be approximately 9.5 mm wide (1) by 12.7 mm in height (2). 3. Allow end of adhesive bead (1) to run out parallel to the start of the bead and smooth ends flush. 4. Lift quarter glass into place in the center of the quarter glass opening and install over the alignment tabs and pin (2). 5. Carefully lay down the quarter glass and press on. CAUTION: It is no longer possible to move the quarter glass after installation. The quarter glass should never be pressed into place by more than one person, because the quarter glass can break if pressed simultaneously on both sides. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing quarter glass to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. 6. Install quarter panel trim. See: Body and Frame/Interior Moulding / Trim/Trim Panel/Service and Repair/Luggage Compartment Trim/Quarter Trim Panel - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal Front Door Window Regulator: Service and Repair Front Door Window Regulator - Removal REMOVAL 1. Remove the watershield. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Water Shield - Removal. 2. Temporarily install the window switch and position the glass (1) to gain access to the regulator nuts (4). 3. Remove the nuts (4). 4. Secure the glass in the up position using a wood wedge or equivalent. 5. Remove the bolts (2) and loosen the remaining regulator bolts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal > Page 10397 6. Separate the regulator (2) from the door panel (1) and disconnect the electrical connector (3). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal > Page 10398 Front Door Window Regulator: Service and Repair Front Door Window Regulator - Installation INSTALLATION 1. Position the regulator (2) into the door (1) and connect the electrical connector (3). 2. Position the regulator bolts into the keyhole slots and slide into place. 3. Install the remaining regulator bolts (2). 4. Tighten the bolts to 9 Nm (80 in. lbs.). 5. Position the glass (1) onto the door regulator (3). 6. Install the nuts (4) and tighten to 9 Nm (80 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Front Door Window Regulator - Removal > Page 10399 7. Install the watershield. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Water Shield - Installation 8. Perform the Clear/Relearn procedure. See: Testing and Inspection/Programming and Relearning Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Removal REMOVAL 1. Remove the watershield. See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Water Shield Removal. 2. Temporarily install the window switch and position the glass (1) to gain access to the regulator nuts (4). 3. Remove the nuts (4). 4. Secure the glass in the up position using a wood wedge or equivalent. 5. Remove the bolts (2) and loosen the remaining regulator bolts. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal > Page 10404 6. Separate the regulator (3) from the door panel (1) and disconnect the electrical connector (2). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal > Page 10405 Rear Door Window Regulator: Service and Repair Rear Door Window Regulator - Installation INSTALLATION 1. Position the regulator (3) into the door (1) and connect the electrical connector (2). 2. Position the regulator bolts into the keyhole slots and slide into place. 3. Install the remaining regulator bolts (2). 4. Tighten the bolts to 9 Nm (80 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Rear Door Window Regulator - Removal > Page 10406 5. Position the glass (1) onto the door regulator (3). 6. Install the nuts (4) and tighten to 9 Nm (80 in. lbs.). 7. Install the watershield. See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Water Shield Installation 8. Perform the Clear/Relearn procedure. See: Testing and Inspection/Programming and Relearning. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Door Glass Channel - Removal Window Track: Service and Repair Door Glass Channel - Removal REMOVAL 1. Raise the glass to the full up position. 2. Remove the watershield. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Water Shield - Removal. 3. Remove the nuts (2) and disconnect the electrical connector (3), if equipped. 4. Remove the side view mirror (1). 5. Separate the inner belt molding from the mounting flange, (from the rear to the front). 6. Insert special tool #9093 (2) between the outer belt molding (1) and glass at the rear. 7. Push down on outer belt molding (1) and rotate the upper part of the tool (2) outward from the vehicle, then lift up on the molding (1) to disengage from the locking tabs (3), working from back to front. NOTE: Typical outer belt molding design shown. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Door Glass Channel - Removal > Page 10411 8. Remove the nut (2), and bolt (3) and the rear glass run channel (1). 9. Remove the bolts 5 and 6. Remove the front glass run channel (4). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Door Glass Channel - Removal > Page 10412 Window Track: Service and Repair Door Glass Channel - Installation INSTALLATION 1. Install the front glass run channel (4) and install bolts 5 and 6. Tighten the bolts to 8 Nm (71 in. lbs.). 2. Install the rear glass run channel and the nut and bolt. 3. Tighten the fasteners to 8 Nm (71 in. lbs.). 4. Position the inner and outer belt molding onto the door and seat fully. 5. Install the side view mirror. 6. Install the nuts and connect the electrical connector. 7. Install the watershield. See: Body and Frame/Doors, Hood and Trunk/Doors/Front Door/Front Door Panel/Service and Repair/Front Door Water Shield - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Door Glass Channel - Removal > Page 10413 Window Track: Service and Repair Rear Door Glass Channel - Removal REMOVAL 1. Raise glass to the up position and remove the watershield. See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Water Shield - Removal. 2. Remove the inner belt molding. 3. Remove the bolt and nut (3) and remove the front channel. 4. Remove the door glass as necessary. See: Window Glass/Rear Door Window Glass/Service and Repair/Rear Door Glass - Removal 5. Remove the bolt (4) and remove the rear glass run channel and stationary glass (1). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Service and Repair > Door Glass Channel - Removal > Page 10414 Window Track: Service and Repair Rear Door Glass Channel - Installation INSTALLATION 1. Install the rear glass run channel and stationary glass (1) into the door and seat fully along the door frame. 2. Install the bolt (4) and tighten to 9 Nm (80 in. lbs.). 3. Install the door glass as necessary except for the inner belt molding. See: Window Glass/Rear Door Window Glass/Service and Repair/Rear Door Glass - Installation 4. Install the front glass run channel and install the bolt and nut (3). 5. Tighten the bolt and nut (3) to 9 Nm (80 in. lbs.). 6. Install the inner belt molding and install the watershield. See: Body and Frame/Doors, Hood and Trunk/Doors/Rear Door/Rear Door Panel/Service and Repair/Water Shield - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions Windshield: Service Precautions WINDSHIELD SAFETY PRECAUTIONS WARNING: Do not operate the vehicle within 24 hours of windshield installation. It takes at least 24 hours for urethane adhesive to cure. If it is not cured, the windshield may not perform properly in an accident. Urethane adhesives are applied as a system. Use glass cleaner, glass prep solvent, glass primer, PVC (vinyl) primer and pinch weld (fence) primer provided by the adhesive manufacturer. If not, structural integrity could be compromised. Chrysler does not recommend glass adhesive by brand. Technicians should review product labels and technical data sheets, and use only adhesives that their manufactures warrant will restore a vehicle to the requirements of FMVSS 212. Technicians should also insure that primers and cleaners are compatible with the particular adhesive used. Be sure to refer to the urethane manufacturer's directions for curing time specifications, and do not use adhesive after its expiration date. Vapors that are emitted from the urethane adhesive or primer could cause personal injury. Use them in a well-ventilated area. Skin contact with urethane adhesive should be avoided. Personal injury may result. Always wear eye and hand protection when working with glass. CAUTION: Protect all painted and trimmed surfaces from coming in contact with urethane or primers. Be careful not to damage painted surfaces when removing moldings or cutting urethane around windshield. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal Windshield: Service and Repair Windshield - Removal REMOVAL 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions 2. Remove the screws (2) attaching the side windshield molding (1) to the a-pillars and remove the molding. 3. Remove rear view mirror. See: Body and Frame/Mirrors/Service and Repair/Interior Rearview Mirror - Removal 4. Remove the cowl grille. See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Cover - Removal 5. Using a windshield cut-out wire separate the adhesive. 6. Carefully remove windshield. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal > Page 10420 Windshield: Service and Repair Windshield - Installation INSTALLATION WARNING: Allow the urethane at least 24 hours to cure before returning the vehicle to use. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing windshield to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. NOTE: The windshield fence should be cleaned of most of its old urethane bonding material. A small amount of old urethane, approximately 1-2 mm in height, should remain on the fence. Do not grind off or completely remove all old urethane from the fence, the paint finish and bonding strength will be adversely affected. Support spacers located on the cowl at the bottom of the windshield opening should be replaced with new parts. Replace any missing or damaged spacers around the perimeter of the windshield opening. Windshield Preparation - Installing A Previously Installed Windshield 1. Before proceeding with the following repair procedure, review all warnings and cautions. See: Service Precautions 2. Level old bead of windshield adhesive (3) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. 3. Apply four new spacers (2) to the A-pillars and place them evenly apart at the top and bottom. 4. Install the lower spacer assemblies (1) into the slotted holes and verify proper installation by pulling to make sure they are locked on. NOTE: Lower spacers must be facing with the flat side upwards when installing into the slotted holes. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal > Page 10421 5. Position windshield (1) in center of windshield opening and resting on the side and lower spacers (2 AND 3). 6. Adjust the lower spacers (3) as required, to obtain the specified roof gap tolerance by pushing on the side of the wedge and raising or lowering the glass as necessary. For roof gap specifications, refer to the table Roof Gap Tolerances. Roof Gap Tolerances 7. Apply adhesive tape (1) to the locations shown to aid with final installation. 8. Verify windshield gap is parallel to with windshield. 9. Cut tape with a sharp knife and remove windshield. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal > Page 10422 NOTE: Typical primer installation shown. 10. Clean and dry area of glass (2) to be re-glued with a suitable glass preparation solvent and rag. 11. Using a flash light, verify that glass primer is without damage. 12. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. 13. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2). 14. Allow primer to air dry for at least 10 minutes. 15. Using a flash light, verify that glass primer is without damage. Windshield Preparation - Installing A New Windshield 1. Apply four new spacers (2) to the A-pillars and place them evenly apart at the top and bottom. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal > Page 10423 2. Install the lower spacer assemblies (1) into the slotted holes and verify proper installation by pulling to make sure they are locked on. NOTE: Lower spacers must be facing with the flat side upwards when installing into the slotted holes. 3. Position windshield (1) in center of windshield opening and resting on the side and lower spacers (2 AND 3). 4. Adjust the lower spacers (3) as required, to obtain the specified roof gap tolerance by pushing on the side of the wedge and raising or lowering the glass as necessary. For roof gap specifications, refer to the table Roof Gap Tolerances. Roof Gap Tolerances 5. Clean and check windshield for damage. 6. Position windshield in center of windshield opening. 7. Apply adhesive tape to the locations shown to aid with final installation. 8. Verify windshield gap is parallel to with windshield. 9. Cut tape with a sharp knife and remove windshield. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal > Page 10424 10. Clean and dry area of glass to be glued with a suitable glass preparation solvent and rag. 11. Apply primer to gluing surface at windshield seal. 12. Apply primer (1) around the perimeter of the glass to a width of 15 mm (0.5 in.) (2). 13. Allow primer to air dry for at least 10 minutes. 14. Using a flash light, verify that glass primer is without damage. Windshield Opening Preparation 1. Clean and vacuum windshield opening. 2. Level old bead of windshield opening adhesive (1) to a thickness of approximately 1 mm (0.04 in.) and remove loose adhesive. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal > Page 10425 3. Clean and dry area of windshield opening to be re-glued with a suitable glass preparation solvent and rag. 4. Re-prime any damaged area. If old adhesive has been exposed for more than 12 hours, entire adhesive area needs to be re-primed. 5. Allow primer to air dry for at least 10 minutes. Windshield Installation 1. Apply bead of adhesive (1) with a triangular nozzle directly to the windshield seal starting at bottom in center of windshield. CAUTION: Always apply bead of adhesive to the windshield. Always install the windshield within 5 minutes after applying adhesive. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Windows and Glass > Windshield > Component Information > Service and Repair > Windshield - Removal > Page 10426 2. Bead dimensions should be approximately 9.5 - 12.0 mm wide (1) by 12.7 - 14.0 mm in height (2). 3. Allow end of adhesive bead to run out parallel to the start of the bead and smooth ends flush. 4. Lift windshield into place in the center of the windshield opening and use the tape as a guide to aid installation of the windshield into the center of the cutout. 5. Carefully lay down windshield and press on. CAUTION: It is no longer possible to move the windshield after installation. The windshield should never be pressed into place by more than one person, because the windshield can break if pressed simultaneously on both sides. CAUTION: Roll down the left and right front door glass and open the rear glass slider (if available) before installing windshield to avoid pressurizing the passenger compartment if a door is slammed before urethane is cured. Water leaks can result. 6. Install cowl grille. See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Cover - Installation 7. Install rear view mirror. See: Body and Frame/Mirrors/Service and Repair/Interior Rearview Mirror - Installation Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Rear Wiper, High/Low, and On/Off Relays are located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Relay-Wiper High/Low Wiper Relay: Diagrams Relay-Wiper High/Low Connector (IN PDC) RELAY-WIPER HIGH/LOW (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Relay-Wiper High/Low > Page 10434 Wiper Relay: Diagrams Relay-Wiper On/Off Connector (IN IPM) RELAY-WIPER ON/OFF (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Relay-Wiper High/Low > Page 10435 Wiper Relay: Diagrams Relay-Wiper-Rear Connector (IN IPM) RELAY-WIPER-REAR (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description Wiper Relay: Description and Operation High and Low Wiper Relay - Description DESCRIPTION The wiper high/low relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper high/low relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. The wiper high/low relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 10438 Wiper Relay: Description and Operation High and Low Wiper Relay - Operation OPERATION The wiper high/low relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the front wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the output of the wiper on/off relay at all times through the wiper on/off relay output circuit. Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper high/low relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current when the ignition switch is in the On or Accessory positions from a fuse in the IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the high speed brush of the wiper motor through a wiper high/low relay high speed output circuit, and is connected to the high speed brush whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to the low speed brush of the wiper motor through a wiper high/low relay low speed output circuit, and is connected to the low speed brush whenever the relay is de-energized. The wiper high/low relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 10439 Wiper Relay: Description and Operation ON and OFF Wiper Relay - Description DESCRIPTION The wiper on/off relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper on/off relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. The wiper on/off relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 10440 Wiper Relay: Description and Operation ON and OFF Wiper Relay - Operation OPERATION The wiper on/off relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper on/off relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper on/off relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the common feed terminal of the wiper high/low relay at all times through the wiper on/off relay output circuit. Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper on/off relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit, and provides battery current to the wiper on/off relay output circuit whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times through a take out of the headlamp and dash wire harness with an eyelet terminal connector that is secured by a screw to the front end sheet metal, and is connected to the wiper on/off relay output circuit whenever the relay is de-energized. The wiper on/off relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 10441 Wiper Relay: Description and Operation High and Low Wiper Relay - Description DESCRIPTION The wiper high/low relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper high/low relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. The wiper high/low relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. High and Low Wiper Relay - Operation OPERATION The wiper high/low relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the front wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the output of the wiper on/off relay at all times through the wiper on/off relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper high/low relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current when the ignition switch is in the On or Accessory positions from a fuse in the IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the high speed brush of the wiper motor through a wiper high/low relay high speed output circuit, and is connected to the high speed brush whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to the low speed brush of the wiper motor through a wiper high/low relay low speed output circuit, and is connected to the low speed brush whenever the relay is de-energized. The wiper high/low relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. ON and OFF Wiper Relay - Description DESCRIPTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 10442 The wiper on/off relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper on/off relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. The wiper on/off relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. ON and OFF Wiper Relay - Operation OPERATION The wiper on/off relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper on/off relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper on/off relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the common feed terminal of the wiper high/low relay at all times through the wiper on/off relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper on/off relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit, and provides battery current to the wiper on/off relay output circuit whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times through a take out of the headlamp and dash wire harness with an eyelet terminal connector that is secured by a screw to the front end sheet metal, and is connected to the wiper on/off relay output circuit whenever the relay is de-energized. The wiper on/off relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Rear Wiper Relay - Description DESCRIPTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 10443 The rear wiper relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The rear wiper relay is located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The rear wiper relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Rear Wiper Relay - Operation OPERATION The rear wiper relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the rear wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear wiper relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the rear wiper relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the rear wiper motor through the rear wiper motor control circuit. When the rear wiper relay is de-energized, the common feed terminal is connected to ground. When the rear wiper relay is energized, the common feed terminal of the relay is connected to battery current from a fuse in the Power Distribution Center (PDC) through a fused B(+) circuit. Coil Ground Terminal - The coil ground terminal (85) is connected to the relay control output of the FCM through the rear wiper relay control circuit. The FCM controls the ground path for this circuit internally to energize or de-energize the rear wiper relay based upon its programming, rear wiper and washer request messages received from the Electro mechanical Instrument Cluster (EMIC) over the Controller Area Network (CAN) data bus, and a hard wired input from the rear wiper motor park switch. - Coil Battery Terminal - The coil battery terminal (86) is connected to battery current from a fuse in the PDC through a fused B(+) circuit at all times. - Normally Open Terminal - The normally open terminal (87) is connected to battery current from a fuse in the PDC through a fused B(+) circuit at all times. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times. The rear wiper relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 10448 Washer Fluid Level Switch: Diagrams Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-WASHER FLUID LEVEL-FRONT REAR - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Washer Fluid Level Switch - Description Washer Fluid Level Switch: Description and Operation Washer Fluid Level Switch - Description DESCRIPTION The washer fluid level switch is a single pole, single throw reed-type switch mounted just above the sump area near the bottom of the washer reservoir. Only the molded plastic switch mounting flange and the integral connector receptacle are visible when the switch is installed in the reservoir. A short nipple formation extends from the inner surface of the switch mounting flange, and a barb on the nipple near the switch mounting flange is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. A molded plastic float rides saddle-like over a molded plastic beam that extends axially from the switch mounting flange. A small permanent magnet is secured in a receptacle on the top of the float, and the reed switch is concealed within the beam. A diagnostic resistor is connected between the two switch terminals within the switch mounting flange. The washer fluid level switch cannot be adjusted or repaired. If ineffective or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Washer Fluid Level Switch - Description > Page 10451 Washer Fluid Level Switch: Description and Operation Washer Fluid Level Switch - Operation OPERATION The washer fluid level switch uses a float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float moves, the proximity of this magnet to a stationary reed switch within the beam formation of the switch changes. When the fluid level in the washer reservoir is at or above the float level, the float rises and the influence of the float magnetic field is removed from the reed switch causing the normally open reed switch contacts to open. When the fluid level in the washer reservoir falls below the level of the float, the float falls and the influence of the float magnetic field is applied to the reed switch, causing the contacts of the normally open reed switch to close. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The switch is connected in series between ground and the washer fluid switch sense input to the Front Control Module (FCM) located in the engine compartment near the battery. The FCM monitors the switch return signal and is programmed to respond to three consecutive open switch readings by sending an electronic washer fluid indicator lamp-ON message to the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch and the hard wired circuits between the switch and the FCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer fluid level switch or the electronic controls or communication between other modules and devices that provide some features of the wiper and washer systems. The most reliable, efficient, and accurate means to diagnose the washer fluid level switch or the electronic controls and communication related to washer fluid level switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Washer Fluid Level Switch - Removal Washer Fluid Level Switch: Service and Repair Washer Fluid Level Switch - Removal REMOVAL NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Reach between the front of the left front wheel house splash shield and the front bumper support to access the rearward facing lower surface of the washer reservoir (1). 3. Disconnect the wire harness connector from the washer fluid level switch (5) connector receptacle. 4. Disconnect the front washer hose from the inboard outlet nipple (3) of the washer pump/motor unit (2) and allow the washer fluid to drain into a clean container for reuse. 5. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the reservoir. Care must be taken not to damage the reservoir. 6. Remove the switch from the reservoir. 7. Remove the rubber grommet seal from the mounting hole in the washer reservoir and discard. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Washer Fluid Level Switch - Removal > Page 10454 Washer Fluid Level Switch: Service and Repair Washer Fluid Level Switch - Installation INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (1). Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the washer fluid level switch (5) through the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be oriented downward. 4. Reconnect the wire harness connector to the switch connector receptacle. 5. Reconnect the front washer hose to the inboard outlet nipple (3) of the washer pump/motor unit (2). 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 10458 Windshield Washer Switch: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Multifunction Switch - Description Windshield Washer Switch: Description and Operation Multifunction Switch - Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Front Washer Control - The multi-function switch control knob provides a momentary front WASH position for front washer system operation. - Front Wiper Control - The multi-function switch control knob provides two continuous front wipe switch positions, LOW speed or HIGH speed; and an intermittent front wipe mode with five delay interval positions. Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Multifunction Switch - Description > Page 10461 Windshield Washer Switch: Description and Operation Multifunction Switch - Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control front washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control front wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Front Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the front WASH mode. The washer pump will continue to operate in the front washer mode until the control knob is released or for 10 continuous seconds, whichever occurs first. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front washer switch status messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The FCM responds by energizing or de-energizing the washer pump in the front washer mode. - Front Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous front wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front wiper switch status messages to the FCM over the CAN data bus. The FCM responds by energizing or de-energizing the wiper on/off and high/low relays in the Power Distribution Center (PDC) for front wiper system control. - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the FCM over the CAN data bus. The FCM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the FCM over the CAN data bus. The FCM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the FCM over the CAN data bus. The FCM energizes and flashes or de-energizes the selected left or right turn signal circuits. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 10462 Windshield Washer Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the multi-function switch from the switch mounting housing on the steering column. See: Lighting and Horns/Sensors and Switches Lighting and Horns/Combination Switch/Service and Repair/Multifunction Switch - Removal. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Multifunction Switch - Removal Windshield Washer Switch: Service and Repair Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10465 8. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 9. Rotate the steering wheel far enough to access and remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 10. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10466 Windshield Washer Switch: Service and Repair Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Rotate the steering wheel far enough to install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. Be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10467 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10471 Wiper Switch: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Multifunction Switch - Description Wiper Switch: Description and Operation Multifunction Switch - Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Front Washer Control - The multi-function switch control knob provides a momentary front WASH position for front washer system operation. - Front Wiper Control - The multi-function switch control knob provides two continuous front wipe switch positions, LOW speed or HIGH speed; and an intermittent front wipe mode with five delay interval positions. Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Multifunction Switch - Description > Page 10474 Wiper Switch: Description and Operation Multifunction Switch - Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control front washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control front wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Front Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the front WASH mode. The washer pump will continue to operate in the front washer mode until the control knob is released or for 10 continuous seconds, whichever occurs first. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front washer switch status messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The FCM responds by energizing or de-energizing the washer pump in the front washer mode. - Front Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous front wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front wiper switch status messages to the FCM over the CAN data bus. The FCM responds by energizing or de-energizing the wiper on/off and high/low relays in the Power Distribution Center (PDC) for front wiper system control. - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the FCM over the CAN data bus. The FCM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the FCM over the CAN data bus. The FCM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the FCM over the CAN data bus. The FCM energizes and flashes or de-energizes the selected left or right turn signal circuits. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10475 Wiper Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the multi-function switch from the switch mounting housing on the steering column. See: Lighting and Horns/Sensors and Switches Lighting and Horns/Combination Switch/Service and Repair/Multifunction Switch - Removal. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch - Removal Wiper Switch: Service and Repair Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10478 8. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 9. Rotate the steering wheel far enough to access and remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 10. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10479 Wiper Switch: Service and Repair Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Rotate the steering wheel far enough to install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. Be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10480 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation > Washer Fluid Level Indicator - Description Washer Fluid Level Indicator: Description and Operation Washer Fluid Level Indicator - Description DESCRIPTION A washer fluid indicator is standard equipment on all instrument clusters. This indicator is located within the odometer/trip odometer Vacuum Fluorescent Display (VFD) unit. However, on vehicles equipped with the optional Electronic Vehicle Information Center (EVIC) the washer fluid indicator in the odometer VFD is electronically suppressed so as not to duplicate indications that are provided by the EVIC. The washer fluid indicator consists of the text LOWASH, which appears in place of the odometer/trip odometer information in the odometer VFD unit. The odometer VFD is soldered onto the cluster electronic circuit board and is visible through a window with a smoked clear lens located on the lower edge of the tachometer gauge dial face of the cluster overlay. The dark lens over the VFD prevents it from being clearly visible when it is not illuminated. The washer fluid indicator appears in the same blue-green color and at the same lighting level as the odometer/trip odometer information when it is illuminated by the instrument cluster electronic circuit board. The washer fluid indicator is serviced as a unit with the instrument cluster. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Description and Operation > Washer Fluid Level Indicator - Description > Page 10485 Washer Fluid Level Indicator: Description and Operation Washer Fluid Level Indicator - Operation OPERATION The washer fluid indicator gives an indication to the vehicle operator that the fluid level in the washer reservoir is low. This indicator is controlled by the instrument cluster logic circuit based upon cluster programming and electronic messages received by the cluster from the Front Control Module (FCM) (also known as the Integrated Power Module/IPM or Power Distribution Center/PDC) over the Controller Area Network (CAN) data bus. The washer fluid indicator function of the Vacuum Fluorescent Display (VFD) is completely controlled by the instrument cluster logic circuit. This logic only allows the indicator to operate when the instrument cluster receives a battery current input on the fused ignition switch output (run-start) circuit. Therefore, the VFD washer fluid indication is always off when the ignition switch is in any position except ON or START. The instrument cluster turns on the washer fluid indicator for the following reasons: - Washer Fluid Indicator Lamp-On Message - Each time the cluster receives an electronic washer fluid indicator lamp-on message from the FCM indicating that a low washer condition has been detected for 60 consecutive seconds, the washer fluid indicator is illuminated and a single chime tone is sounded. The indicator remains illuminated until the cluster receives lamp-off messages for 60 consecutive seconds from the FCM, or until the ignition switch is turned to the OFF position, whichever occurs first. The chime tone feature only repeats during the same ignition cycle if the washer fluid indicator is cycled off then on again by the appropriate lamp-on and lamp-off messages from the FCM. The FCM continually monitors the washer fluid level switch in the washer reservoir to determine the level of the washer fluid. The FCM then sends the proper lamp-on or lamp-off message to the instrument cluster, also known as the Cab Compartment Node (CCN). For further diagnosis of the washer fluid indicator or the instrument cluster circuitry that controls the indicator, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection. Use a diagnostic scan tool for proper diagnosis of the washer fluid level switch, the FCM, the CCN, the CAN data bus or the electronic communication related to washer fluid indicator operation. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 10489 Washer Fluid Level Switch: Diagrams Connector - (HEADLAMP AND DASH) 2 WAY SENSOR-WASHER FLUID LEVEL-FRONT REAR - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Washer Fluid Level Switch - Description Washer Fluid Level Switch: Description and Operation Washer Fluid Level Switch - Description DESCRIPTION The washer fluid level switch is a single pole, single throw reed-type switch mounted just above the sump area near the bottom of the washer reservoir. Only the molded plastic switch mounting flange and the integral connector receptacle are visible when the switch is installed in the reservoir. A short nipple formation extends from the inner surface of the switch mounting flange, and a barb on the nipple near the switch mounting flange is pressed through a rubber grommet seal installed in the mounting hole of the reservoir. A molded plastic float rides saddle-like over a molded plastic beam that extends axially from the switch mounting flange. A small permanent magnet is secured in a receptacle on the top of the float, and the reed switch is concealed within the beam. A diagnostic resistor is connected between the two switch terminals within the switch mounting flange. The washer fluid level switch cannot be adjusted or repaired. If ineffective or damaged, it must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Description and Operation > Washer Fluid Level Switch - Description > Page 10492 Washer Fluid Level Switch: Description and Operation Washer Fluid Level Switch - Operation OPERATION The washer fluid level switch uses a float to monitor the level of the washer fluid in the washer reservoir. The float contains a small magnet. When the float moves, the proximity of this magnet to a stationary reed switch within the beam formation of the switch changes. When the fluid level in the washer reservoir is at or above the float level, the float rises and the influence of the float magnetic field is removed from the reed switch causing the normally open reed switch contacts to open. When the fluid level in the washer reservoir falls below the level of the float, the float falls and the influence of the float magnetic field is applied to the reed switch, causing the contacts of the normally open reed switch to close. The washer fluid level switch is connected to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The switch is connected in series between ground and the washer fluid switch sense input to the Front Control Module (FCM) located in the engine compartment near the battery. The FCM monitors the switch return signal and is programmed to respond to three consecutive open switch readings by sending an electronic washer fluid indicator lamp-ON message to the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) over the Controller Area Network (CAN) data bus. The EMIC responds to this message by illuminating the washer fluid indicator and by sounding an audible chime tone warning. The washer fluid level switch and the hard wired circuits between the switch and the FCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer fluid level switch or the electronic controls or communication between other modules and devices that provide some features of the wiper and washer systems. The most reliable, efficient, and accurate means to diagnose the washer fluid level switch or the electronic controls and communication related to washer fluid level switch operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Washer Fluid Level Switch - Removal Washer Fluid Level Switch: Service and Repair Washer Fluid Level Switch - Removal REMOVAL NOTE: The washer fluid level switch can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Reach between the front of the left front wheel house splash shield and the front bumper support to access the rearward facing lower surface of the washer reservoir (1). 3. Disconnect the wire harness connector from the washer fluid level switch (5) connector receptacle. 4. Disconnect the front washer hose from the inboard outlet nipple (3) of the washer pump/motor unit (2) and allow the washer fluid to drain into a clean container for reuse. 5. Using a trim stick or another suitable wide flat-bladed tool, gently pry the barbed nipple of the washer fluid level switch out of the rubber grommet seal in the reservoir. Care must be taken not to damage the reservoir. 6. Remove the switch from the reservoir. 7. Remove the rubber grommet seal from the mounting hole in the washer reservoir and discard. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Service and Repair > Washer Fluid Level Switch - Removal > Page 10495 Washer Fluid Level Switch: Service and Repair Washer Fluid Level Switch - Installation INSTALLATION 1. Install a new rubber grommet seal into the washer fluid level switch mounting hole in the washer reservoir (1). Always use a new rubber grommet seal on the reservoir. 2. Insert the nipple formation of the washer fluid level switch (5) through the rubber grommet seal in the reservoir. 3. Using hand pressure, press firmly and evenly on the switch mounting flange until the barbed nipple is fully seated in the rubber grommet seal in the reservoir. The flat edge of the switch mounting flange should be oriented downward. 4. Reconnect the wire harness connector to the switch connector receptacle. 5. Reconnect the front washer hose to the inboard outlet nipple (3) of the washer pump/motor unit (2). 6. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 7. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation > Front Washer Hoses and Tubes - Description Windshield Washer Hose: Description and Operation Front Washer Hoses and Tubes - Description FRONT The front washer plumbing consists of a small diameter rubber hose (4) that is routed along with the rear washer hose (3) from the washer reservoir (6) under the left front fender (2) ahead of the left front wheel to the engine compartment. Both hoses are attached to their respective front or rear outlet nipple of the washer pump/motor unit (5) near the bottom of the reservoir. The hoses are then secured by a retainer to the underside of the Power Distribution Center (PDC) bracket (1) above the wheel house splash shield before entering the left side of the engine compartment behind the PDC. In the engine compartment, both hoses are secured by a retainer near the dash panel to the side support member for the left front fender (5). The two hoses are routed separately from this point. The front hose (4) is routed up toward the hood (3), while the rear hose (6) is routed through a grommet and a hole in the dash panel into the passenger compartment. The front hose is secured by molded plastic retainers near the right end of the cowl panel to the hood hinge bracket and to the underside of the hood panel reinforcement. A molded rubber tee fitting provides the take out for the left washer nozzle (2), and a molded rubber elbow terminate provides the connection to the right washer nozzle (1). Washer hose is available for service only as roll stock, which must then be cut to length. The molded plastic washer hose fittings cannot be repaired. If these fittings are ineffective or damaged, they must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation > Front Washer Hoses and Tubes - Description > Page 10500 Windshield Washer Hose: Description and Operation Rear Washer Hoses and Tubes - Description REAR The rear washer plumbing consists of a small diameter rubber hose that is routed along with the front washer hose from the washer reservoir under the left front fender ahead of the left front wheel to the engine compartment. Both hoses are attached to their respective front or rear outlet nipple of the washer pump/motor unit near the bottom of the reservoir. The hoses are then secured by retainers to the back of the condenser shroud and the underside of the Power Distribution Center (PDC) bracket above the wheel house splash shield before entering the left side of the engine compartment behind the PDC. In the engine compartment, both hoses are secured by a retainer near the dash panel to the side support member for the left front fender. The two hoses are routed separately from this point. The front hose is routed up toward the hood, while the rear hose (2) is routed through a grommet and a hole in the dash panel (3) into the passenger compartment. The hose is then routed below the instrument panel to the left cowl side inner panel and up the left inner A-pillar (4). Midway up the A-pillar the hose is connected with a molded plastic in-line fitting to the headliner hose (1). The headliner hose (2) large rubber grommet is secured above the headliner (3) from the A-pillar to the upper liftgate opening inner panel (4). Near the center of the liftgate, the hose passes through a small rubber grommet in a clearance hole in the upper liftgate inner panel and through the washer nozzle mounting hole in the liftgate outer panel to the rear washer nozzle. Washer hose is available for service only as roll stock, which must then be cut to length. The molded plastic washer hose fittings and routing clips cannot be repaired. If these fittings or clips are ineffective or damaged, they must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation > Front Washer Hoses and Tubes - Description > Page 10501 Windshield Washer Hose: Description and Operation Front Washer Hoses and Tubes - Operation FRONT Washer fluid in the washer reservoir is pressurized and fed by the washer pump/motor unit through the front washer system plumbing and fittings to the two front washer nozzles. Whenever routing the washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Description and Operation > Front Washer Hoses and Tubes - Description > Page 10502 Windshield Washer Hose: Description and Operation Rear Washer Hoses and Tubes - Operation REAR Washer fluid in the washer reservoir is pressurized and fed by the washer pump/motor unit through the rear washer system plumbing and fittings to the rear washer nozzle located on the liftgate outer panel above the liftgate glass. Whenever routing the washer hose or a wire harness containing a washer hose, it must be routed away from hot, sharp, or moving parts; and, sharp bends that might pinch the hose must be avoided. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations > Page 10506 Windshield Washer Pump: Diagrams Connector - (HEADLAMP AND DASH) 2 WAY PUMP-WASHER-WINDSHIELD - (HEADLAMP AND DASH) 2 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation > Windshield Washer Pump - Description Windshield Washer Pump: Description and Operation Windshield Washer Pump - Description DESCRIPTION The washer pump/motor unit is located on the rearward facing side of the washer reservoir, in the left front fender wheel house ahead of the front wheel and the left front wheel house splash shield. A small permanently lubricated and sealed reversible electric motor (3) is coupled to the rotor-type washer pump (4). The use of an integral valve body (7) allows the washer pump/motor unit to provide washer fluid to either the front or the rear washer systems, depending upon the direction of the pump impeller rotation. An inlet nipple (6) on the pump housing passes through a rubber grommet seal/filter screen installed in a dedicated mounting hole of the washer reservoir sump. The filter screen prevents most debris from entering the pump housing. When the pump is installed in the reservoir the front barbed outlet nipple (5) on the pump valve body housing connects the unit to the front washer hose, and the rear barbed outlet nipple (8) connects the unit to the rear washer hose. The letters F and R molded into the valve body housing adjacent to each nipple provide further clarification of the nipple assignments. The washer pump/motor unit is retained on the reservoir by the interference fit between the pump inlet nipple and the grommet seal, and by a snap post (2) at the top of the pump motor housing that is engaged into a receptacle on the reservoir which is a light snap fit. An integral connector receptacle (1) on the top of the motor housing connects the unit to the vehicle electrical system through a dedicated take out and connector of the headlamp and dash wire harness. The washer pump/motor unit cannot be repaired. If ineffective or damaged, the entire washer pump/motor unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Description and Operation > Windshield Washer Pump - Description > Page 10509 Windshield Washer Pump: Description and Operation Windshield Washer Pump - Operation OPERATION The washer pump/motor unit features a reversible electric motor. The direction of the motor is controlled by hard wired outputs from the Front Control Module (FCM). When battery current and ground are applied to the two pump motor terminals, the motor rotates in one direction. When the polarity of these connections is reversed, the motor rotates in the opposite direction. When the pump motor is energized, the rotor-type pump pressurizes the washer fluid and forces it through one of the two pump outlet nipples, and into the front or rear washer plumbing. The FCM controls the hard wired outputs to the pump motor based upon electronic washer request messages received over the Controller Area Network (CAN) data bus from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN). The EMIC monitors a resistor multiplexed input from the front washer switch circuitry contained within the multi-function switch, and electronic rear washer switch status messages received over the CAN data bus from the A/C-heater control on the instrument panel to determine the proper washer request message to send. Whenever the low washer fluid indicator is illuminated, the EMIC is programmed to suppress all rear washer requests in order to give priority to the need for forward visibility. Washer fluid is gravity-fed from the washer reservoir to the inlet port of the washer pump housing. An integral valve body is located in a housing on the outlet port side (2) of the pump housing. A diaphragm (4) in this valve body controls which washer system plumbing receives the washer fluid being pressurized by the pump. When the pump is not operating the diaphragm is biased to close all washer fluid flow in the rear washer system and, in this way it also performs the function of the rear washer system check valve. When the pump impeller (1) rotates in the counterclockwise direction (viewed from the bottom), the biased diaphragm is sealing off the rear washer system outlet and nipple so the pressurized washer fluid is pushed out through the pump front outlet port and the front washer outlet nipple (5). When the pump impeller rotates in the clockwise direction (viewed from the bottom), pressurized washer fluid is pushed out through the pump rear outlet port and moves the diaphragm to open the rear washer outlet nipple and seal off the front washer outlet nipple, then the pressurized washer fluid is pushed out through the rear washer outlet nipple (3). The washer pump/motor unit and the hard wired motor control circuits from the FCM may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the washer pump/motor unit or the electronic controls or communication between other modules and devices that provide some features of the front and rear wiper and washer system. The most reliable, efficient, and accurate means to diagnose the washer pump/motor unit or the electronic controls and communication related to washer pump/motor unit operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Windshield Washer Pump - Removal Windshield Washer Pump: Service and Repair Windshield Washer Pump - Removal REMOVAL NOTE: The washer pump/motor unit can be removed from the washer reservoir without removing the reservoir from the vehicle. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Reach between the front of the left front wheel house splash shield and the front bumper support to access the rearward facing lower surface of the washer reservoir (1). 3. Disconnect the wire harness connector from the top of the washer pump/motor unit (2). 4. Disconnect the front washer hose from the inboard pump outlet nipple (3) and allow the washer fluid to drain into a clean container for reuse. 5. Disconnect the rear washer hose from the outboard pump outlet nipple (4). 6. Grasp the top of the washer pump/motor housing and pull it firmly rearward far enough to disengage the snap post on the top of the motor from the receptacle in the reservoir. 7. Grasp the lower part of the washer pump/motor housing and, using a back and forth twisting action, pull the unit upward from the reservoir far enough to disengage the pump inlet nipple from the rubber grommet seal/filter screen in the reservoir. 8. Remove the rubber grommet seal/filter screen from the washer pump mounting hole in the reservoir and discard. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Windshield Washer Pump - Removal > Page 10512 Windshield Washer Pump: Service and Repair Windshield Washer Pump - Installation INSTALLATION 1. Install a new rubber grommet seal/filter screen into the washer pump mounting hole of the washer reservoir (1). Always use a new rubber grommet seal/filter screen on the reservoir. 2. Position the inlet nipple of the washer pump/motor unit (2) to the rubber grommet seal/filter screen in the reservoir. 3. Using hand pressure, press downward on the lower part of the washer pump firmly and evenly until the inlet nipple is fully seated in the rubber grommet seal/filter screen in the reservoir. 4. Align the snap post on the top of the motor housing with the snap post receptacle in the washer reservoir. 5. Using hand pressure, press firmly and evenly on the top of motor housing until the post snaps into the receptacle. 6. Reconnect the rear washer hose to the outboard pump outlet nipple (4). 7. Reconnect the front washer hose to the inboard pump outlet nipple (3). 8. Reconnect the wire harness connector to the top of the pump motor. 9. Refill the washer reservoir with the washer fluid drained from the reservoir during the removal procedure. 10. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Windshield Washer Reservoir - Description Windshield Washer Reservoir: Description and Operation Windshield Washer Reservoir Description DESCRIPTION The molded plastic washer fluid reservoir is integral to the engine coolant overflow bottle located on the left end of the air conditioning condenser module in the left front corner of the engine compartment. A single washer fluid reservoir is used for both the front and rear washer systems. A bright yellow plastic filler cap with a rubber seal and an International Control and Display Symbol icon for Windshield Washer and the text WASHER FLUID ONLY molded into it snaps over the open end of the filler neck. The cap hinges on and is secured to a molded-in hook formation on the top of the reservoir just behind the filler neck when it is removed for inspecting or adjusting the fluid level in the reservoir. There are separate, dedicated holes on the lower rearward facing side of the reservoir provided for the mounting of the washer/pump motor unit and the washer fluid level switch. A snap post receptacle for the washer pump is molded into the reservoir to allow for mounting of the washer pump/motor unit without the use of fasteners. The washer reservoir is serviced only as a unit with the engine coolant reserve bottle. The washer reservoir cannot be repaired and, if ineffective or damaged, the coolant reserve bottle/washer reservoir unit must be replaced. The grommet seals for the washer pump/motor unit and the washer fluid level switch, and the filler cap are each available for individual service replacement. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Description and Operation > Windshield Washer Reservoir - Description > Page 10517 Windshield Washer Reservoir: Description and Operation Windshield Washer Reservoir Operation OPERATION The washer fluid reservoir provides a secure, on-vehicle storage location for a large reserve of washer fluid for operation of the front and rear washer systems. The washer reservoir filler neck provides a clearly marked and readily accessible point from which to add washer fluid to the reservoir. The washer/pump motor unit is located in a sump area near the bottom of the reservoir to be certain that washer fluid will be available to the pump as the fluid level in the reservoir becomes depleted. The washer fluid level switch is mounted just above the sump area of the reservoir so that there will be adequate warning to the vehicle operator that the washer fluid level is low, before the front washer system will no longer operate. The Electro mechanical Instrument Cluster (EMIC) is programmed to suppress rear washer system operation upon illumination of the low washer fluid indicator so that the front washers can remain operational until the fluid level can be replenished. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Washer Nozzle - Description Windshield Washer Spray Nozzle: Description and Operation Washer Nozzle - Description Front FRONT The fluidic front washer nozzles (2) are constructed of molded plastic. Each nozzle has two integral latches that secure them in dedicated holes in the hood panel near the base of the windshield. A check valve is integral to each front washer nozzle. The domed upper surface of the washer nozzle is visible on the outside of the hood panel, and the nozzle orifice (1) is oriented towards the windshield glass. The washer plumbing fittings (4) for the washer nozzles extend below the hood panel and are accessible from the engine compartment. The front washer nozzles cannot be adjusted or repaired and, if ineffective or damaged, they must be replaced. Rear REAR The rear washer nozzle (3) is a fluidic-type unit constructed of molded plastic. The nozzle is secured by a snap fit in a dedicated mounting hole in the liftgate outer panel above the liftgate glass with the orifice (5) aimed downward. A rubber gasket (2) seals the nozzle to the outside of the liftgate panel. The back of the nozzle includes an integral alignment feature (4), an engagement tab (1), a latch feature (6) and the washer plumbing nipple (7) which are all concealed between the liftgate inner and outer panels when the nozzle is installed. The rear washer nozzle latch feature is a one time component, and will be damaged if the nozzle is removed from its mounting hole for service. The rear washer nozzle unit cannot be adjusted or repaired. If ineffective or damaged, the entire nozzle unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Description and Operation > Washer Nozzle - Description > Page 10522 Windshield Washer Spray Nozzle: Description and Operation Washer Nozzle - Operation Front FRONT The two front washer nozzles are designed to dispense washer fluid into the wiper pattern area on the outside of the windshield glass. Pressurized washer fluid is fed to each nozzle from the washer reservoir by the washer pump/motor unit through a single hose, which is attached to a barbed nipple on each washer nozzle below the hood panel. A fluidic matrix within the washer nozzle causes the pressurized washer fluid to be emitted from the nozzle orifice as an oscillating stream to more effectively cover a larger area of the glass to be cleaned. The integral check valve prevents washer fluid from draining out of the washer supply hoses back to the washer reservoir. This drain-back would result in a delay from when the washer pump is energized until washer fluid was dispensed through the nozzles. Such a drain-back condition could also result in water, dirt, or other outside contaminants being siphoned into the washer system through the washer nozzle orifice. This water could subsequently freeze and plug the nozzle, while other contaminants could interfere with proper nozzle operation and cause improper nozzle spray patterns. When the washer pump pressurizes and pumps washer fluid from the reservoir through the washer plumbing, the fluid pressure unseats a diaphragm from over a sump well within the nozzle. With the diaphragm unseated, washer fluid is allowed to flow through the washer nozzle. When the washer pump stops operating, the diaphragm seats over the sump well in the valve and fluid flow in either direction within the washer plumbing is prevented. Rear REAR The rear washer nozzle is designed to dispense washer fluid into the wiper pattern area on the outside of the liftgate glass. Pressurized washer fluid is fed to the nozzle from the washer reservoir by the washer pump/motor unit through a single hose, which is attached to a barbed nipple on the back of the rear washer nozzle. A fluidic matrix within the washer nozzle causes the pressurized washer fluid to be emitted from the nozzle orifice as an oscillating stream to more effectively cover a larger area of the glass to be cleaned. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Washer Nozzle - Removal Windshield Washer Spray Nozzle: Service and Repair Washer Nozzle - Removal Front FRONT 1. Insert a trim stick or another suitable wide flat-bladed tool between the front or rear edge of the washer nozzle (1) and the hood panel (2) to depress one of the nozzle latches. 2. Holding the latch depressed, lift upward on the same edge of the nozzle to disengage it from the hood. 3. Pull the nozzle away from the hood far enough to access and disconnect the hose from the barbed nipple of the nozzle. 4. Remove the nozzle from the top of the hood panel. Rear REAR NOTE: The rear washer nozzle latch feature is a one time component, and will be damaged if the nozzle is removed from its mounting hole for service. If removed from its mounting hole for any reason, the rear washer nozzle must be replaced with a new unit. 1. Using a trim stick or another suitable wide flat-bladed tool, gently pry at the bottom of the rear washer nozzle (2) to release the latch feature that secures it in the mounting hole of the liftgate outer panel (3). 2. Pull the rear washer nozzle out from the liftgate outer panel far enough to access the washer hose (1). 3. Disconnect the hose from the barbed nipple on the back of the nozzle. 4. Cut 4 to 6 millimeters (0.15 to 0.23 inch) from the end of the hose to ensure a good fit to the replacement washer nozzle. 5. Discard the nozzle. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information > Service and Repair > Washer Nozzle - Removal > Page 10525 Windshield Washer Spray Nozzle: Service and Repair Washer Nozzle - Installation Front FRONT 1. Position the front washer nozzle (1) near the mounting hole on the outside of the hood panel (2). 2. Reconnect the washer hose to the barbed nipple of the nozzle. 3. Insert the nozzle into the mounting hole. 4. Using hand pressure, push firmly and evenly on the top of the nozzle until the integral latches lock into place on the underside of the outer hood panel. Rear REAR NOTE: The rear washer nozzle latch feature is a one time component, and will be damaged if the nozzle is removed from its mounting hole for service. If removed from its mounting hole for any reason, the rear washer nozzle must be replaced with a new unit. 1. Position the new rear washer nozzle (2) to the mounting hole in the liftgate outer panel (3). Be certain that the rubber gasket is in position on the back of the nozzle. 2. Reconnect the washer hose (1) to the barbed nipple on the back of the nozzle. 3. Push the hose and nozzle nipple into the mounting hole in the liftgate outer panel and engage the tab located above the nipple with the upper edge of the hole. 4. Using hand pressure, push firmly and evenly on the lower edge of the nozzle until it snaps into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 10529 Windshield Washer Switch: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Multifunction Switch - Description Windshield Washer Switch: Description and Operation Multifunction Switch - Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Front Washer Control - The multi-function switch control knob provides a momentary front WASH position for front washer system operation. - Front Wiper Control - The multi-function switch control knob provides two continuous front wipe switch positions, LOW speed or HIGH speed; and an intermittent front wipe mode with five delay interval positions. Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Multifunction Switch - Description > Page 10532 Windshield Washer Switch: Description and Operation Multifunction Switch - Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control front washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control front wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Front Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the front WASH mode. The washer pump will continue to operate in the front washer mode until the control knob is released or for 10 continuous seconds, whichever occurs first. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front washer switch status messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The FCM responds by energizing or de-energizing the washer pump in the front washer mode. - Front Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous front wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front wiper switch status messages to the FCM over the CAN data bus. The FCM responds by energizing or de-energizing the wiper on/off and high/low relays in the Power Distribution Center (PDC) for front wiper system control. - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the FCM over the CAN data bus. The FCM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the FCM over the CAN data bus. The FCM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the FCM over the CAN data bus. The FCM energizes and flashes or de-energizes the selected left or right turn signal circuits. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Description and Operation > Page 10533 Windshield Washer Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the multi-function switch from the switch mounting housing on the steering column. See: Lighting and Horns/Sensors and Switches Lighting and Horns/Combination Switch/Service and Repair/Multifunction Switch - Removal. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Multifunction Switch - Removal Windshield Washer Switch: Service and Repair Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10536 8. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 9. Rotate the steering wheel far enough to access and remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 10. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10537 Windshield Washer Switch: Service and Repair Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Rotate the steering wheel far enough to install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. Be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.). Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10538 9. Position the tilt steering column knob (1) onto the tilt adjuster actuator (3) on the left side of the steering column, then install and tighten the screw (2) to secure the knob to the actuator. Tighten the screw to 2 Nm (20 in. lbs.). 10. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Wiper Arm - Description Wiper Arm: Description and Operation Wiper Arm - Description Front FRONT The front wiper arms are the rigid members located between the wiper pivots protruding from the cowl plenum cover/grille panel near the base of the windshield and the wiper blades on the windshield glass. Both wiper arms feature an over-center hinge (3) that allows easy access to the windshield glass for cleaning. The wiper arms each have a die cast metal pivot end. The left arm has a large tapered mounting hole on the pivot end that is secured by a nut to the left wiper pivot. The unique, articulated right wiper arm has two pivoting links attached to the arm pivot end. A drive link (5) is secured by a nut to the right wiper pivot and is the unit that drives the right wiper arm. The articulating link (6) is secured by a nut to a drone pivot located outboard of the right wiper pivot on the wiper module bracket. The right wiper arm pivot end and the connections of both links to the arm are concealed beneath a molded black plastic appearance cover (4). The wide end of a tapered, stamped steel channel (2) hinges on and is secured with a hinge pin to the blade end of both the right and left wiper arm pivot ends. One end of a long, rigid, stamped steel strap (1), with a small hole near its pivot end, is riveted and crimped within the narrow end of the stamped steel channel. The tip of the wiper blade end of this strap is bent back under itself to form a small hook. Concealed within the stamped steel channel, one end of a long spring is engaged with a wire hook on the underside of the die cast pivot end, while the other end of the spring is hooked through the small hole in the steel strap. The entire wiper arm has a satin black finish applied to all of its visible surfaces. A wiper arm cannot be adjusted or repaired. If damaged or ineffective, the entire wiper arm unit must be replaced. Rear REAR Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Wiper Arm - Description > Page 10543 The rear wiper arm (1) is the rigid member located between the rear wiper motor output shaft that protrudes from the outer liftgate panel near the base of the liftgate glass opening and the rear wiper blade (2). The wiper arm is constructed of molded black plastic. A hinged pivot end is also molded plastic, except for a tapered metal sleeve that receives the wiper motor output shaft and a plate where the arm retaining nut is supported. A molded black plastic cap (4) with an engagement tab on one side and a snap feature on the other fits in the hole over the wiper arm retaining nut to conceal the nut and mounting hole following wiper arm installation. The wiper arm hinge, pivot block and tension spring are all concealed on the underside of the wide end of the arm. The matching wiper blade unit has two pivot pins that latch into a receptacle concealed within the narrow end of the arm. The rear wiper arm cannot be adjusted or repaired. If damaged or ineffective, the entire wiper arm unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Description and Operation > Wiper Arm - Description > Page 10544 Wiper Arm: Description and Operation Wiper Arm - Operation Front FRONT The front wiper arms are designed to mechanically transmit the motion from the wiper pivots to the wiper blades. The wiper arm must be properly indexed to the wiper pivot in order to maintain the proper wiper blade travel on the glass. The combination of the drive link, articulating link, wiper arm pivot end, the drone pivot and the wiper module bracket creates a four link system that articulates the wiping action of the right wiper arm to effectively clear a larger area of the windshield glass. The tapered mounting hole in the left wiper arm pivot end or in the right wiper arm links interlock with the serrations on the tapered outer circumference of the wiper pivot shafts and the drone pivot, allowing positive engagement and finite adjustment of these connections. The mounting nuts lock the wiper arms to the threaded studs of the pivot shafts. The spring-loaded wiper arm hinge controls the down-force applied through the tip of the wiper arm to the wiper blade on the glass. The hook formation on the tip of the wiper arm provides a cradle for securing and latching the wiper blade pivot block to the wiper arm. Rear REAR The rear wiper arm is designed to mechanically transmit the motion from the rear wiper motor output shaft to the rear wiper blade. The wiper arm must be properly indexed to the motor output shaft in order to maintain the proper wiper blade travel on the glass. The tapered hole in the wiper arm pivot end interlocks with the serrations on the outer circumference of the tapered motor output shaft, allowing positive engagement and finite adjustment of this connection. A hex nut secures the wiper arm pivot end to the threads on the rear wiper motor output shaft and the plastic nut cap snaps over this connection for a neat appearance. The spring-loaded wiper arm hinge controls the down-force applied through the tip of the wiper arm to the wiper blade on the glass. The receptacle formation on the tip of the wiper arm provides a cradle for securing and latching the wiper blade to the wiper arm. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm - Removal Wiper Arm: Service and Repair Wiper Arm - Removal Front FRONT 1. Lift the front wiper arm to its over-center position to hold the wiper blade off of the glass and relieve the spring tension on the wiper arm to wiper pivot shaft connection. 2. Remove the nut or nuts (2) that secure the front wiper arm (1) or links to the pivot shaft or shafts (3 and 4). 3. If necessary, use a suitable battery terminal puller (3) to disengage the front wiper arm (1) or links from the pivot shaft (2) or shafts. 4. Remove the wiper arm pivot end or links from the pivot shaft or shafts. Rear REAR Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm - Removal > Page 10547 1. Insert the tip of a small screwdriver into the notch on the large end of the rear wiper arm (1) and carefully pry the plastic cap (6) until it unsnaps from the mounting hole on the pivot end of the arm. 2. Remove the nut (5) that secures the arm to the rear wiper motor output shaft (3). CAUTION: The use of a battery terminal puller when removing the rear wiper arm is NOT recommended as this may damage the rear wiper arm. 3. Use a slight rocking action to remove the rear wiper arm from the output shaft. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm - Removal > Page 10548 Wiper Arm: Service and Repair Wiper Arm - Installation Front FRONT NOTE: Be certain that the wiper motor is in the park position before attempting to install the front wiper arms. Turn the ignition switch to the On position and move the multi-function switch control knob to its Off position. If the wiper pivots move, wait until they stop moving, then turn the ignition switch back to the Off position. The front wiper motor is now in its park position. 1. The front wiper arms (1) must be indexed to the pivot shafts (3 and 4) with the front wiper motor in the park position to be properly installed. Position the wiper arm pivot end or links onto the pivot shafts so that the lower edge of the wiper blade is aligned with the wiper alignment lines (5) concealed in the upper margin of the lower windshield blackout area. 2. Once the wiper blade is aligned, lift the front wiper arm away from the windshield slightly to relieve the spring tension on the pivot end or links and push the arm or links down over the pivot shaft or shafts. 3. Install and tighten the nut or nuts (2) that secure the wiper arm or links to the pivot shaft or shafts. Tighten the nuts to 44.5 Nm (33 ft. lbs.). 4. Wet the windshield glass, then operate the front wipers. Turn the wiper switch to the Off position, then check for the correct wiper arm position and readjust as required. Rear REAR NOTE: Be certain that the rear wiper motor is in the park position before attempting to install the wiper arm. Turn the ignition switch to the On position and move the rear wiper switch to its Off position. If the wiper motor output shaft moves, wait until it stops moving, then turn the ignition switch back to the Off position. The wiper motor is now in its park position. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Wiper Arm - Removal > Page 10549 1. The rear wiper arm (1) must be indexed to the motor output shaft (3) with the rear wiper motor in the park position to be properly installed. Position the rear wiper arm pivot end onto the motor output shaft so that the wiper blade is aligned with the alignment mark (4) located in the upper margin of the lower liftgate glass blackout area on the lower right corner of the liftgate glass. 2. With the wiper arm properly indexed, push the tapered mounting hole on the pivot end of the wiper arm down over the output shaft. 3. Install and tighten the nut (5) that secures the arm to the shaft. Tighten the nut to 12 Nm (9 ft. lbs.). 4. Wet the liftgate glass, then operate the rear wiper. Turn the rear wiper switch to the Off position, then check for the correct wiper arm position and adjust as required. 5. Insert the tab of the plastic cap (6) into the mounting hole on the side opposite the notch and press firmly on the notched side of the cap until it snaps into place. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Description and Operation > Wiper Blade - Description Wiper Blade: Description and Operation Wiper Blade - Description Front FRONT Each front wiper blade is secured by an integral latching pivot block (3) to the hook formation on the tip of each wiper arm, and rests on the glass near the base of the windshield when the wipers are not in operation. The wiper blade consists of the following components: - Superstructure (1) - The superstructure includes several stamped steel bridges and links with claw formations that grip the wiper blade element. Also included in this unit is the latching, molded plastic pivot block that secures the superstructure to the wiper arm. All of the metal components of the wiper blade have a satin black finish applied. - Element (2) - The wiper element or squeegee is the resilient rubber member of the wiper blade that contacts the glass. - Flexor (7) - The flexor is a rigid metal component running along the length of each side of the wiper element where it is gripped by the claws (6) of the superstructure. The flexor is also designed to provide a predetermined curvature that best fits the curvature of glass throughout the wipe pattern. The right wiper blade is 53.00 centimeters (20.87 inches) long, and the left blade is 65.09 centimeters (25.63 inches) long. Both have non-replaceable rubber elements (squeegees). The wiper blades cannot be adjusted or repaired. If ineffective, worn, or damaged the entire wiper blade unit must be replaced. Rear REAR The rear wiper blade is secured by two integral latching pivot pins (1) to a receptacle in the small end at the tip of the rear wiper arm, and rests near the base of the liftgate glass when the wiper is not in operation. The rear wiper blade consists of the following components: - Superstructure (4) - The superstructure includes a molded black plastic bridge and plastic links with claw formations that grip the wiper blade Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Description and Operation > Wiper Blade - Description > Page 10554 element. Also included in this unit are the two latching pivot pins that secure the superstructure to the wiper arm. - Element (2) - The wiper element or squeegee is the resilient rubber member of the wiper blade that contacts the glass. - Flexor (3) - The flexor is a rigid metal component running along the length of each side of the wiper element where it is gripped by the claws of the superstructure. The rear wiper blade is 30.10 centimeters (11.85 inches) long with a replaceable element (squeegee). The wiper blade superstructure cannot be adjusted or repaired. If ineffective, worn, or damaged the entire wiper blade unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Description and Operation > Wiper Blade - Description > Page 10555 Wiper Blade: Description and Operation Wiper Blade - Operation Front FRONT The wiper blades are moved back and forth across the glass by the wiper arms when the wipers are being operated. The wiper blade superstructure is the flexible frame that grips the wiper blade element and evenly distributes the force of the spring-loaded wiper arm along the length of the element. The combination of the wiper arm force and the flexibility of the superstructure makes the element conform to and maintain proper contact with the glass, even as the blade is moved over the varied curvature that may be encountered across the glass surface. The wiper element flexor provides the claws of the blade superstructure with a rigid, yet flexible component on the element which can be gripped. The rubber element is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass, yet resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions. Rear REAR The rear wiper blade is moved back and forth across the liftgate glass by the wiper arm when the rear wiper system is in operation. The wiper blade superstructure is the flexible frame that grips the wiper blade element and evenly distributes the force of the spring-loaded wiper arm along the length of the element. The combination of the wiper arm force and the flexibility of the superstructure makes the element conform to and maintain proper contact with the glass, even as the blade is moved over the varied curvature found across the glass surface. The wiper element flexor provides the claws of the blade superstructure with a rigid, yet flexible component on the element which can be gripped. The rubber element is designed to be stiff enough to maintain an even cleaning edge as it is drawn across the glass, but resilient enough to conform to the glass surface and flip from one cleaning edge to the other each time the wiper blade changes directions. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade - Rear Wiper Element Replacement Wiper Blade: Service and Repair Wiper Blade - Rear Wiper Element Replacement REAR WIPER ELEMENT REPLACEMENT 1. Remove the rear wiper blade (3) from the wiper arm. See: Wiper Blade - Removal. 2. Grasp one of the wiper blade links (4) firmly with one hand, and grasp the wiper element (1) and flexor (2) midway between the two sets of claws (5) for that link with the other hand. 3. Pull the element and flexor away from the link until they flex enough to disengage them from the end pair of claws. 4. Slide the element and flexor toward the loose end to disengage them from the remaining sets of claws. 5. Reverse this process to install a new element and flexors into the wiper blade. 6. Reinstall the wiper blade into the wiper arm. See: Wiper Blade - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade - Rear Wiper Element Replacement > Page 10558 Wiper Blade: Service and Repair Wiper Blade - Removal Front FRONT CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm (2) to raise the wiper blade and element (6) off of the glass, until the wiper arm hinge is in its over-center position. 2. To remove the blade from the arm, depress the latch release tab (4) on the pivot block (3) under the tip of the arm and slide the blade away from the tip towards the pivot end of the arm far enough to disengage the pivot block from the hook formation (5) on the end of the arm. 3. Extract the hook formation on the tip of the wiper arm through the opening in the wiper blade superstructure (1) just ahead of the pivot block. 4. Gently lower the tip of the wiper arm onto the glass. Rear REAR 1. Lift the rear wiper arm (3) to raise the wiper blade (1) and element off of the liftgate glass. 2. To remove the wiper blade from the wiper arm, squeeze the two latch release tabs (2) together while pulling the blade straight out from the receptacle in the end of the arm. CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass and the wiper arm may be damaged. 3. Gently lower the tip of the wiper arm onto the glass. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Blade - Rear Wiper Element Replacement > Page 10559 Wiper Blade: Service and Repair Wiper Blade - Installation Front FRONT CAUTION: Do not allow the wiper arm to spring back against the glass without the wiper blade in place or the glass may be damaged. NOTE: The notched end of the wiper element flexor should always be oriented towards the end of the wiper blade that is nearest to the wiper pivot. 1. Lift the wiper arm (2) off of the windshield glass, until the wiper arm hinge is in its over-center position. 2. Position the wiper blade near the hook formation (5) on the tip of the arm with the notched end of the wiper element flexor oriented towards the end of the wiper arm that is nearest to the wiper pivot. 3. Insert the hook formation on the tip of the arm through the opening in the blade superstructure (1) ahead of the pivot block (3) far enough to engage the pivot block into the hook. 4. Slide the pivot block up into the hook formation on the tip of the wiper arm until the latch release tab (4) snaps into its locked position. Latch engagement will be accompanied by an audible click. 5. Gently lower the wiper blade and element (6) onto the glass. Rear REAR 1. Lift the rear wiper arm (3) off of the liftgate glass. 2. Position the rear wiper blade (1) with the latching pivot pins aligned with the receptacle on the tip of the arm. 3. Slide the wiper blade pivot pins into the receptacle until they snap into place. 4. Lower the wiper blade onto the glass. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Description and Operation > Wiper Transmission - Description Wiper Gear Box: Description and Operation Wiper Transmission - Description DESCRIPTION The front wiper module is secured with screws through four rubber grommet-type insulators (4) to the cowl plenum panel and the left front fender ledge. The module is located in the rear of the engine compartment where it is concealed beneath the molded plastic cowl plenum cover/grille panel between the base of the windshield and the rear edge of the hood panel. The ends of the pivot shafts protruding through openings in the cowl plenum cover/grille panel are the only visible components of the wiper module. The wiper module consists of the following major components: - Bracket (5) - The wiper module bracket is a single die cast aluminum unit that includes provisions for mounting the wiper motor and wiper pivots as well as for the for rubber insulators used in mounting the bracket to the vehicle. - Crank Arm (6) - The wiper motor crank arm is a stamped steel unit with an internally splined hole on the driven end that is secured to the wiper motor output shaft with a nut, and has a long ball stud secured to the drive end to accept the wiper linkage. - Linkage (3) - The two wiper linkage members are each constructed of stamped steel. A driver side drive link with a plastic socket-type bushing in the left end, and a plastic sleeve-type bushing in the right end. The socket bushing is snap-fit over the pivot ball stud on the left pivot lever arm, while the sleeve bushing is fit over the longer pivot stud on the wiper motor crank arm. The passenger side drive link has a plastic socket-type bushing on each end. One end of this drive link is snap-fit over the ball stud on the right pivot lever arm, while the other end is snap-fit over the top of the driver side drive link on the ball stud of the wiper motor crank arm. - Motor (7) - The wiper motor is secured on the underside of the module bracket near the center with three screws. The wiper motor output shaft passes through a hole in the module bracket, where a nut secures the wiper motor crank arm to the motor output shaft. The two-speed permanent magnet wiper motor features an integral transmission, an internal park switch, and an internal Positive Temperature Coefficient (PTC) circuit breaker. - Pivots (1 and 2) - This module features two driven pivots (2) and one drone pivot (1) for the articulating link of the right wiper arm. The two driven wiper pivot shafts have lever arms with ball studs at their base to accept the wiper linkage. The upper end of all three pivot shafts has a threaded stud with a tapered and serrated area just below the threads to accept the left wiper arm or the right wiper arm links. The front wiper module cannot be adjusted or repaired. The front wiper motor is available for separate service replacement. If any other component of the module is ineffective or damaged, the entire front wiper module unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Description and Operation > Wiper Transmission - Description > Page 10564 Wiper Gear Box: Description and Operation Wiper Transmission - Operation OPERATION The front wiper module operation is controlled by the battery current inputs received by the wiper motor through the wiper on/off and wiper high/low relays. The wiper motor speed is controlled by current flow to either the low speed or the high speed set of brushes. The park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately opens and closes the wiper park switch sense circuit to ground, depending upon the position of the wipers on the glass. This feature allows the motor to complete its current wipe cycle after the wiper system has been turned OFF, and to park the wiper blades in the lowest portion of the wipe pattern. The automatic resetting circuit breaker protects the motor from overloads. The wiper motor crank arm, the two wiper linkage members, and the two driven wiper pivots mechanically convert the rotary output of the wiper motor to the back and forth wiping motion of the wiper arms and blades on the glass. The drone pivot provides an anchor point for the articulating link of the right wiper arm. The hard wired inputs and outputs of the front wiper motor may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods will not prove conclusive in the diagnosis of the front wiper motor or the electronic controls or communication between other modules and devices that provide some features of the front wiper and washer system. The most reliable, efficient, and accurate means to diagnose the front wiper motor or the electronic controls and communication related to front wiper motor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Wiper Transmission - Removal Wiper Gear Box: Service and Repair Wiper Transmission - Removal REMOVAL NOTE: The front wiper motor can be removed from the wiper module without removing the module from the vehicle, and is available as a separate service component for this vehicle. See: Wiper Motor/Service and Repair/Wiper Motor Removal . 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove both front wiper arms from the wiper pivots. See: Wiper Arm/Service and Repair/Wiper Arm - Removal. 3. Remove the cowl plenum cover/grille panel from over the front wiper module. See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Cover - Removal. 4. Disconnect the wire harness connector (5) from the front wiper motor connector. 5. Remove the screw (3) that secures the front wiper module bracket (6) and the center bracket of the cowl grille support (7) to the cowl plenum panel (1). 6. Remove the three screws (2) that secure the module bracket to the cowl plenum panel and the left front fender ledge. 7. Remove the wiper module from the engine compartment as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair > Wiper Transmission - Removal > Page 10567 Wiper Gear Box: Service and Repair Wiper Transmission - Installation INSTALLATION 1. Check to be certain that the rivet nut (4) used to secure the front wiper module (6) is properly installed in the support at the left front fender ledge, and that it is in good condition. 2. Position the front wiper module to the cowl plenum panel (1) as a unit. 3. Install and tighten the three screws (2) that secure the module bracket to the cowl plenum panel and the left front fender ledge. Tighten the screws to 9 Nm (80 in. lbs.). 4. Install and tighten the screw (3) that secures the module bracket and the center bracket of the cowl grille support (7) to the cowl plenum panel. Tighten the screw to 9 Nm (80 in. lbs.). 5. Reconnect the wire harness connector (5) to the front wiper motor connector. 6. Reinstall the cowl plenum cover/grille panel over the front wiper module. See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Cover - Installation. 7. Reinstall both front wiper arms onto the wiper pivots. See: Wiper Arm/Service and Repair/Wiper Arm - Installation. 8. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Rear Wiper Motor Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Locations > Rear Wiper Motor > Page 10572 Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Rear Wiper Motor (Liftgate) 3 Way Wiper Motor: Diagrams Rear Wiper Motor (Liftgate) 3 Way Connector - (LIFTGATE) 3 WAY MOTOR-REAR WINDOW WIPER - (LIFTGATE) 3 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Rear Wiper Motor (Liftgate) 3 Way > Page 10575 Wiper Motor: Diagrams Windshield Wiper Motor (Headlamp And Dash) 4 Way Connector - (HEADLAMP AND DASH) 4 WAY MOTOR-WINDSHIELD WIPER - (HEADLAMP AND DASH) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Wiper Motor - Description Wiper Motor: Description and Operation Wiper Motor - Description REAR The rear wiper motor (2) is concealed within the liftgate, below the liftgate glass and behind the liftgate inner trim panel. The end of the motor output shaft (1) that extends through the liftgate outer panel to drive the rear wiper arm and blade is the only visible component of the rear wiper motor. A rubber bezel and grommet is engaged within the output shaft hole of the liftgate outer panel and seals the output shaft where it passes through the panel. An integral connector receptacle (4) connects the rear wiper motor to the vehicle electrical system through a dedicated take out and connector of the liftgate wire harness. The rear wiper motor consists of the following major components: - Bracket (5) - The rear wiper motor bracket consists of a molded plastic mounting plate for the wiper motor that is secured with screws to the wiper motor housing, and through three rubber isolators (3) to the liftgate inner panel. - Motor - The single-speed permanent magnet rear wiper motor is secured with screws to the rear wiper motor bracket. The wiper motor includes an integral transmission, a motor output shaft, an automatic resetting circuit breaker, and the rear wiper motor park switch. The rear wiper motor cannot be adjusted or repaired. If any component of the motor is ineffective or damaged, the entire rear wiper motor unit must be replaced. The motor output shaft bezel and grommet, nut, and nut cover are available for individual service replacement. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Description and Operation > Wiper Motor - Description > Page 10578 Wiper Motor: Description and Operation Wiper Motor - Operation REAR The rear wiper motor operation is controlled by the rear wiper relay, which controls battery current flow to the rear wiper motor brushes based upon control outputs from the Front Control Module (FCM). The FCM uses internal programming, hard wired outputs from the rear wiper motor park switch, and electronic messages received over the Controller Area Network (CAN) data bus from the Electro mechanical Instrument Cluster (EMIC) and from rear wiper and washer switches in the heater-A/C control to determine when to energize or de-energize the rear wiper relay. The rear wiper motor park switch is a single pole, single throw, momentary switch within the wiper motor that is mechanically actuated by the wiper motor transmission components. The park switch alternately closes and opens a path to ground for the rear wiper motor control circuit input to the FCM, depending upon the position of the rear wiper blade on the liftgate glass. This feature allows the FCM to monitor the number of rear wiper motor cycles, as well as to keep the rear wiper relay energized long enough for the motor to complete its current wipe cycle after the wiper system or the ignition has been turned OFF, and to park the wiper blade in the lowest portion of the wipe pattern. The rear wiper motor is grounded at all times through a take out with an eyelet terminal connector in the body wire harness that is secured to a ground location in the passenger compartment. The automatic resetting circuit breaker protects the motor from overloads. The rear wiper motor transmission converts the rotary output of the wiper motor to the back and forth wiping motion of the rear wiper arm and blade on the liftgate glass. The hard wired inputs and outputs of the rear wiper motor may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. However, conventional diagnostic methods may not prove conclusive in the diagnosis of the rear wiper motor, the EMIC, the FCM, the heater-A/C control, the CAN data bus or the electronic communication between these modules. The most reliable, efficient, and accurate means to diagnose the rear wiper motor, the EMIC, the FCM, the heater-A/C control, the CAN data bus or the electronic communication related to rear wiper motor operation requires the use of a diagnostic scan tool. Refer to the appropriate diagnostic information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Removal Wiper Motor: Service and Repair Wiper Motor - Removal Front FRONT CAUTION: Do not apply pressure to, or pry on, the plastic drive link bushing. When removing the drive link from, or installing the drive link to the ball stud on the wiper motor crank arm, apply pressure to, or pry on, only the metal portions of the drive link around the bushing. If the bushing is damaged, the entire front wiper module MUST be replaced. CAUTION: Do not remove the crank arm nut from the wiper motor output shaft. The crank arm is indexed to the output shaft with the motor in the park position during the manufacturing process, but there are no provisions made for correctly indexing this connection in the field. If the crank arm to output shaft indexing is incorrect, the entire front wiper module MUST be replaced. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove both front wiper arms from the wiper pivots. See: Wiper Arm/Service and Repair/Wiper Arm - Removal. 3. Remove the cowl plenum cover/grille panel from over the front wiper module. See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Cover - Removal. 4. Disconnect the wire harness connector from the front wiper motor connector. 5. Disengage the socket bushing (3) of the right wiper drive link (2) from the ball stud on the wiper motor crank arm (5) using two large screwdrivers, one on each side of the ball stud. Pry between the crank arm and the metal portion of the drive link until the socket unsnaps from the ball. 6. Remove the sleeve bushing of the left wiper drive link (4) from the ball stud on the wiper motor crank arm. 7. While supporting the wiper motor (7) from the underside of the wiper module bracket (6), remove the three screws (1) that secure the motor to the bracket. 8. Remove the wiper motor and crank arm unit from the underside of the module bracket. Rear REAR Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Removal > Page 10581 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the rear wiper arm (1) from the rear wiper motor output shaft (3). See: Wiper Arm/Service and Repair/Wiper Arm - Removal. NOTE: The output shaft bezel and grommet (2) does not have to be removed to remove the rear wiper motor from the liftgate. 3. Remove the trim panel from the liftgate inner panel (2). See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Removal. 4. Disconnect the wire harness connector from the rear wiper motor (3). 5. Remove the three screws (4) that secure the motor mounting bracket to the liftgate inner panel. 6. Remove the motor from the liftgate. 7. Remove the bezel and rubber grommet on the outer liftgate panel from the output shaft housing. Be certain to take proper precautions to protect the outer liftgate panel and its paint finish from damage during this procedure. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Removal > Page 10582 Wiper Motor: Service and Repair Wiper Motor - Installation Front FRONT CAUTION: Do not apply pressure to, or pry on, the plastic drive link bushing. When removing the drive link from, or installing the drive link to the ball stud on the wiper motor crank arm, apply pressure to, or pry on, only the metal portions of the drive link around the bushing. If the bushing is damaged, the entire front wiper module MUST be replaced. CAUTION: Do not remove the crank arm nut from the wiper motor output shaft. The crank arm is indexed to the output shaft with the motor in the park position during the manufacturing process, but there are no provisions made for correctly indexing this connection in the field. If the crank arm to output shaft indexing is incorrect, the entire front wiper module MUST be replaced. 1. Position the front wiper motor (7) and crank arm (5) unit to the front wiper module bracket (6) from the underside of the bracket. 2. Install and tighten the three screws (1) that secure the motor to the bracket. Tighten the screws to 7 Nm (62 in. lbs.). 3. Position the left wiper drive link (4) sleeve bushing (2) over the ball stud (3) on the end of the motor crank arm (1). 4. Place a short 19 millimeter or 3/4 inch socket over the sleeve bushing as an installation tool. Then use large channel-lock pliers to apply enough pressure to the underside of the crank arm and the top of the socket to snap the bushing over the upper ball and onto the lower ball of the ball stud. Do not apply pressure directly to the plastic bushing and do not press the bushing beyond the lower ball of the ball stud. CAUTION: Carefully inspect the installed sleeve bushing (2) to be certain it is centered over the lower ball of the ball stud (3), and not trapped between the lower ball and the crank arm (1). There should be a visible clearance between the lower surface of the sleeve bushing and the crank arm. Refer to the accompanying illustration. The sleeve bushing must be able to swivel freely on the lower ball during wiper operation. If the bushing is trapped between the lower ball and the crank arm, the bushing and the drive link (4) may be damaged. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Removal > Page 10583 5. Position the socket bushing of the right wiper drive link over the ball stud on the crank arm. 6. Place a short 19 millimeter or 3/4 inch socket over the capped side of the bushing as an installation tool. Then use large channel-lock pliers to apply enough pressure to the underside of the crank arm and the top of the socket to snap the bushing onto the ball stud. Do not apply pressure directly to the plastic bushing. 7. Reconnect the wire harness connector to the wiper motor connector. 8. Reinstall the cowl plenum cover/grille panel over the front wiper module. See: Body and Frame/Cowl/Cowl Moulding / Trim/Service and Repair/Cowl Panel Cover - Installation. 9. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. 10. Turn the ignition switch to the ON position, then turn the front wiper switch ON and OFF again to cycle the wiper motor and linkage to their natural park positions before reinstalling the front wiper arms onto the wiper pivots. 11. Reinstall both front wiper arms onto the wiper pivots. See: Wiper Arm/Service and Repair/Wiper Arm - Installation. Rear REAR 1. If the output shaft bezel and grommet were removed from the outside of the liftgate, install the rubber bezel and grommet into the mounting hole of the liftgate outer panel. 2. Check to be certain that the three rivet nuts (1) used to secure the rear wiper motor and bracket unit (3) are properly installed in the liftgate inner panel (2), and that they are in good condition. 3. Position the motor into the liftgate as a unit. 4. Install and tighten the three screws (4) that secure the mounting bracket to the liftgate. Tighten the screws to 8 Nm (72 in. lbs.). 5. Reconnect the wire harness connector to the motor connector receptacle. 6. Reinstall the trim panel onto the liftgate inner panel. See: Body and Frame/Doors, Hood and Trunk/Trunk / Liftgate/Trunk / Liftgate Interior Trim Panel/Service and Repair/Liftgate Trim Panel - Installation. 7. Reinstall the rear wiper arm (1) onto the output shaft (3). See: Wiper Arm/Service and Repair/Wiper Arm - Installation. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor - Removal > Page 10584 8. Reconnect the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also reinstall the high voltage service disconnect into the high voltage battery pack. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations Wiper Relay: Locations Rear Wiper, High/Low, and On/Off Relays are located in the Integrated Power Module (IPM). Integrated Power Module (IPM) Integrated Power Module (IPM) is located in the engine compartment, next to the battery. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Relay-Wiper High/Low Wiper Relay: Diagrams Relay-Wiper High/Low Connector (IN PDC) RELAY-WIPER HIGH/LOW (IN PDC) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Relay-Wiper High/Low > Page 10590 Wiper Relay: Diagrams Relay-Wiper On/Off Connector (IN IPM) RELAY-WIPER ON/OFF (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Relay-Wiper High/Low > Page 10591 Wiper Relay: Diagrams Relay-Wiper-Rear Connector (IN IPM) RELAY-WIPER-REAR (IN IPM) Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description Wiper Relay: Description and Operation High and Low Wiper Relay - Description DESCRIPTION The wiper high/low relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper high/low relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. The wiper high/low relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 10594 Wiper Relay: Description and Operation High and Low Wiper Relay - Operation OPERATION The wiper high/low relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the front wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the output of the wiper on/off relay at all times through the wiper on/off relay output circuit. Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper high/low relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current when the ignition switch is in the On or Accessory positions from a fuse in the IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the high speed brush of the wiper motor through a wiper high/low relay high speed output circuit, and is connected to the high speed brush whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to the low speed brush of the wiper motor through a wiper high/low relay low speed output circuit, and is connected to the low speed brush whenever the relay is de-energized. The wiper high/low relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 10595 Wiper Relay: Description and Operation ON and OFF Wiper Relay - Description DESCRIPTION The wiper on/off relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper on/off relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. The wiper on/off relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 10596 Wiper Relay: Description and Operation ON and OFF Wiper Relay - Operation OPERATION The wiper on/off relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper on/off relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper on/off relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the common feed terminal of the wiper high/low relay at all times through the wiper on/off relay output circuit. Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper on/off relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit, and provides battery current to the wiper on/off relay output circuit whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times through a take out of the headlamp and dash wire harness with an eyelet terminal connector that is secured by a screw to the front end sheet metal, and is connected to the wiper on/off relay output circuit whenever the relay is de-energized. The wiper on/off relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 10597 Wiper Relay: Description and Operation High and Low Wiper Relay - Description DESCRIPTION The wiper high/low relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper high/low relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. The wiper high/low relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. High and Low Wiper Relay - Operation OPERATION The wiper high/low relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the front wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper high/low relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper high/low relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the output of the wiper on/off relay at all times through the wiper on/off relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper high/low relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current when the ignition switch is in the On or Accessory positions from a fuse in the IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) is connected to the high speed brush of the wiper motor through a wiper high/low relay high speed output circuit, and is connected to the high speed brush whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to the low speed brush of the wiper motor through a wiper high/low relay low speed output circuit, and is connected to the low speed brush whenever the relay is de-energized. The wiper high/low relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. ON and OFF Wiper Relay - Description DESCRIPTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 10598 The wiper on/off relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The wiper on/off relay is located in the Integrated Power Module (IPM) in the engine compartment near the battery. Refer to the layout label on the underside of the IPM cover for specific relay cavity assignment information. The wiper on/off relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. ON and OFF Wiper Relay - Operation OPERATION The wiper on/off relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The wiper on/off relay terminals are connected to the vehicle electrical system through a connector receptacle in the Integrated Power Module (IPM). The inputs and outputs of the wiper on/off relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the common feed terminal of the wiper high/low relay at all times through the wiper on/off relay output circuit. - Coil Ground Terminal - The coil ground terminal (85) is connected to a control output of the Front Control Module (FCM) through a wiper on/off relay control circuit. The FCM controls wiper motor operation by controlling a ground path through this circuit. - Coil Battery Terminal - The coil battery terminal (86) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit. - Normally Open Terminal - The normally open terminal (87) receives battery current at all times from a fuse in the IPM through a fused ignition switch output (run-acc) circuit, and provides battery current to the wiper on/off relay output circuit whenever the relay is energized. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times through a take out of the headlamp and dash wire harness with an eyelet terminal connector that is secured by a screw to the front end sheet metal, and is connected to the wiper on/off relay output circuit whenever the relay is de-energized. The wiper on/off relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Rear Wiper Relay - Description DESCRIPTION Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Description and Operation > High and Low Wiper Relay - Description > Page 10599 The rear wiper relay is a conventional International Standards Organization (ISO) micro relay. Relays conforming to the ISO specifications have common physical dimensions, current capacities, terminal patterns, and terminal functions. This relay is contained within a small, rectangular, molded plastic housing and is connected to all of the required inputs and outputs through five integral male spade-type terminals that extend from the relay base plate. The rear wiper relay is located in the Power Distribution Center (PDC) in the engine compartment near the battery. Refer to the layout label on the underside of the PDC cover for specific relay cavity assignment information. The rear wiper relay cannot be adjusted or repaired and, if ineffective or damaged, the unit must be replaced. Rear Wiper Relay - Operation OPERATION The rear wiper relay is an electromechanical switch that uses a low current input from the Front Control Module (FCM) to control a high current output to the rear wiper motor. The movable common feed contact point is held against the fixed normally closed contact point by spring pressure. When the relay coil is energized, an electromagnetic field is produced by the coil windings. This electromagnetic field draws the movable relay contact point away from the fixed normally closed contact point, and holds it against the fixed normally open contact point. When the relay coil is de-energized, spring pressure returns the movable contact point back against the fixed normally closed contact point. A resistor is connected in parallel with the relay coil in the relay, and helps to dissipate voltage spikes and electromagnetic interference that can be generated as the electromagnetic field of the relay coil collapses. The rear wiper relay terminals are connected to the vehicle electrical system through a connector receptacle in the Power Distribution Center (PDC). The inputs and outputs of the rear wiper relay include: - Common Feed Terminal - The common feed terminal (30) is connected to the rear wiper motor through the rear wiper motor control circuit. When the rear wiper relay is de-energized, the common feed terminal is connected to ground. When the rear wiper relay is energized, the common feed terminal of the relay is connected to battery current from a fuse in the Power Distribution Center (PDC) through a fused B(+) circuit. Coil Ground Terminal - The coil ground terminal (85) is connected to the relay control output of the FCM through the rear wiper relay control circuit. The FCM controls the ground path for this circuit internally to energize or de-energize the rear wiper relay based upon its programming, rear wiper and washer request messages received from the Electro mechanical Instrument Cluster (EMIC) over the Controller Area Network (CAN) data bus, and a hard wired input from the rear wiper motor park switch. - Coil Battery Terminal - The coil battery terminal (86) is connected to battery current from a fuse in the PDC through a fused B(+) circuit at all times. - Normally Open Terminal - The normally open terminal (87) is connected to battery current from a fuse in the PDC through a fused B(+) circuit at all times. - Normally Closed Terminal - The normally closed terminal (87A) is connected to ground at all times. The rear wiper relay as well as the hard wired inputs and outputs of the relay may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 10603 Wiper Switch: Diagrams Connector - (INSTRUMENT PANEL) 4 WAY SWITCH-MULTIFUNCTION - (INSTRUMENT PANEL) 4 WAY Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Multifunction Switch - Description Wiper Switch: Description and Operation Multifunction Switch - Description DESCRIPTION The multi-function switch (3) is located on the steering column, just below the steering wheel. The only visible components of the multi-function switch are the control stalk (2) and control knob (1) that extend through the steering column shrouds on the left side of the column, and the hazard warning push button (4) that extends through the shroud on the top of the column. The remainder of the switch including its mounting provisions, its electrical connection, and the turn signal cancel actuator (5) are concealed beneath the shrouds. The switch housing and controls are constructed of molded black plastic. Each of the switch controls has white International Control and Display Symbol graphics applied to it, which clearly identify its many functions. Three integral locating posts on the switch housing, one on the top and two on the bottom, slide into channels in a receptacle on the left side of the multi-function switch mounting housing near the top of the steering column to ensure proper positioning of the switch. Then two screws secure the switch to the mounting housing. A single integral connector receptacle containing four terminal pins on the back of the switch housing connects the switch to the vehicle electrical system through a dedicated take out and connector of the instrument panel wire harness. The multi-function switch provides the vehicle operator with a control interface for the following functions: - Front Washer Control - The multi-function switch control knob provides a momentary front WASH position for front washer system operation. - Front Wiper Control - The multi-function switch control knob provides two continuous front wipe switch positions, LOW speed or HIGH speed; and an intermittent front wipe mode with five delay interval positions. Hazard Warning Control - The multi-function switch hazard warning push button provides two detent positions (ON and OFF) to control the hazard warning lamps. - Headlamp Beam Selection - The multi-function switch control stalk provides detent switching for selection of the headlamp HIGH or LOW beams. There is also an intermediate momentary position that allows the headlamp high beam circuits to be momentarily flashed to provide an optical horn feature (sometimes referred to as flash-to-pass) as an optical signalling device. - Turn Signal Control - The multi-function switch control stalk provides momentary non-detent (lane change) switching or detent switching with automatic cancellation for both the left and right turn signal lamps. The multi-function switch cannot be adjusted or repaired. If any function of the switch is ineffective, or if the switch is damaged, the entire switch must be replaced as a unit. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Multifunction Switch - Description > Page 10606 Wiper Switch: Description and Operation Multifunction Switch - Operation OPERATION The multi-function switch uses resistor multiplexing to control the many functions and features it provides using only three hard wired output circuits. The switch receives a clean ground from the Electro mechanical Instrument Cluster (EMIC) (also known as the Cab Compartment Node/CCN) on a multi-function switch return circuit. It then provides outputs to the EMIC on a wash/beam select switch signal circuit to control front washer and headlamp beam selection, on an intermittent wiper switch signal circuit to control front wipers, and on a turn lamps switch signal circuit to control turn signal and hazard warning functions. The multi-function switch operates as follows: - Front Washer Control - The control knob on the end of the multi-function switch control stalk is depressed towards the steering column to momentarily activate the washer pump in the front WASH mode. The washer pump will continue to operate in the front washer mode until the control knob is released or for 10 continuous seconds, whichever occurs first. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front washer switch status messages to the Front Control Module (FCM) over the Controller Area Network (CAN) data bus. The FCM responds by energizing or de-energizing the washer pump in the front washer mode. - Front Wiper Control - The control knob on the end of the multi-function switch control stalk is rotated to one of the continuous front wiper detents, to one of five intermittent wiper detents, or to the OFF position to select the front wiper mode. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic front wiper switch status messages to the FCM over the CAN data bus. The FCM responds by energizing or de-energizing the wiper on/off and high/low relays in the Power Distribution Center (PDC) for front wiper system control. - Hazard Warning Control - The hazard warning push button of the multi-function switch is depressed to activate the hazard warning system, and depressed again to turn the system OFF. When the push button is actuated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic hazard switch status messages to the FCM over the CAN data bus. The FCM then energizes and flashes or de-energizes both the left and right turn signal circuits to provide the visual hazard warning. - Headlamp Beam Selection - The control stalk of the multi-function switch is pulled towards the steering wheel past a detent to actuate the integral beam select switch circuitry, or to an intermediate, momentary position before the detent to actuate the optical horn feature. Each time the control stalk is actuated to a detent position, the opposite headlamp beam from what is currently selected will be energized. Each time the control stalk is actuated to the momentary position with the headlamps turned OFF, the headlamp high beams will be illuminated for as long as the control stalk is held in this position. The multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic beam select switch status messages to the FCM over the CAN data bus. The FCM energizes or de-energizes the selected LOW or HIGH beam circuits. - Turn Signal Control - The control stalk of the multi-function switch is moved upward to activate the RIGHT turn signal circuitry, and, downward to activate the LEFT turn signal circuitry. The turn signal switch has a detent position in each direction that provides turn signals with automatic cancellation, and an intermediate, momentary position in each direction that automatically provides three turn signal blinks as a LANE CHANGE feature when the control stalk is tapped or will energize the turn signals for as long as the control stalk is held in the momentary position. When the control stalk is moved to a detent turn signal switch position, the cancel actuator extends toward the center of the steering column. A turn signal cancel cam that is integral to the clockspring rotates with the steering wheel and the cam lobes contact the cancel actuator when it is extended from the multi-function switch. When the steering wheel is rotated during a turning maneuver, one of the two turn signal cancel cam lobes will contact the turn signal cancel actuator. The cancel actuator latches against the cancel cam rotation in the direction opposite that which is signaled. If the LEFT turn signal detent is selected, the lobes of the cancel cam will ratchet past the cancel actuator when the steering wheel is rotated to the left, but will unlatch the cancel actuator as the steering wheel rotates to the right and returns to center, which will cancel the turn signal event and release the control stalk from the detent so it returns to the neutral OFF position. When a turn signal is activated, the multi-function switch provides an output to the EMIC, and the EMIC responds by sending electronic turn signal switch status messages to the FCM over the CAN data bus. The FCM energizes and flashes or de-energizes the selected left or right turn signal circuits. The multi-function switch as well as the hard wired inputs and outputs of the switch may be diagnosed using conventional diagnostic tools and procedures. Refer to the appropriate wiring information. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Description and Operation > Page 10607 Wiper Switch: Testing and Inspection MULTI-FUNCTION SWITCH WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Remove the multi-function switch from the switch mounting housing on the steering column. See: Lighting and Horns/Sensors and Switches Lighting and Horns/Combination Switch/Service and Repair/Multifunction Switch - Removal. 2. Disconnect the wire harness connector from the back of the multi-function switch. 3. Using an ohmmeter, test the resistance between the terminals of the switch as shown in the Multi-Function Switch Tests table. 4. If the switch fails any of the tests, replace the ineffective multi-function switch as required. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch - Removal Wiper Switch: Service and Repair Multifunction Switch - Removal REMOVAL WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Disconnect and isolate the battery negative cable. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. 2. Remove the screw (2) that secures the tilt steering column knob (1) and remove it from the tilt actuator (3) on the left side of the column. 3. From below the steering column, remove the two outboard screws that secure the upper column shroud (1) to the lower shroud (3). 4. Using hand pressure, press inward on both sides of the upper shroud above the parting line of the lower shroud to release the snap features that secure the two shroud halves to each other. 5. Remove the upper shroud from the lower shroud and the steering column. 6. Remove the one center screw that secures the lower shroud to the steering column (4). 7. Remove the lower shroud from the steering column. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10610 8. Disconnect the wire harness connector (2) from the back of the multi-function switch housing (1). 9. Rotate the steering wheel far enough to access and remove the two screws (4) that secure the switch to the multi-function switch mounting housing (3). 10. Grasp the switch control stalk and pull it toward the left side of the vehicle to remove the switch from the mounting housing. Dodge Durango 4wd Workshop Manual (V8-5.7L Hybrid (2009)) Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair > Multifunction Switch - Removal > Page 10611 Wiper Switch: Service and Repair Multifunction Switch - Installation INSTALLATION WARNING: To avoid serious or fatal injury on vehicles equipped with airbags, disable the Supplemental Restraint System (SRS) before attempting any steering wheel, steering column, airbag, seat belt tensioner, impact sensor or instrument panel component diagnosis or service. Disconnect and isolate the negative battery (ground) cable. Wait two minutes for the system capacitor to discharge before performing further diagnosis or service. On vehicles equipped with the optional Hybrid Electric Vehicle (HEV) system, a technician trained in proper HEV service safety procedures must also remove the high voltage service disconnect from the high voltage battery pack. This is the only sure way to disable the SRS. Failure to take the proper precautions could result in accidental airbag deployment. Failure to follow these instructions may result in possible serious or fatal injury. 1. Slide the multi-function switch (1) into the multi-function switch mounting housing (3) from the left side. Be certain that the alignment pins on the top and bottom of the switch are properly engaged in the channels of the mounting housing. 2. Rotate the steering wheel far enough to install and tighten the two screws (4) that secure the switch to the mounting housing. Tighten the screws to 2 Nm (20 in. lbs.). 3. Reconnect the wire harness connector (2) to the back of the switch. 4. Position the lower shroud (3) onto the steering column (4). 5. From below the steering column, install and tighten the one center screw that secures the lower shroud to the steering column. Tighten the screw to 2 Nm (20 in. lbs.). 6. Position the upper shroud (1) onto the steering column over the lower shroud. Be certain to engage the gearshift lever gap hider into the opening in the right side of both shroud halves. 7. Align the snap features on the upper shroud with the receptacles in the lower shroud and apply hand pressure to snap them together. 8. Install and tighten the two outboard screws that secure the upper shroud to the lower shroud. Tighten the screws to 2 Nm (20 in. lbs.).